Toyota Prius: Front Suspension Member

• Removal
• Installation

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during front suspension crossmember sub-assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
*: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation. *1: Also necessary after performing a tire rotation. *2: It is not necessary to perform this procedure if the tire pressure warning valve and transmitters are installed to the same location. *3: The Toyota Prius vehicle height changes because of tire replacement. *4: If matchmarks were not placed when removing parts related to steering operation, perform end position initial setting.
Front wheel alignment adjustment	Perform "Calibration"	DTCs are stored ABS warning light illuminates Brake system warning light (yellow indicator) illuminates Slip indicator light illuminates Electronically controlled brake system disabled or malfunctions
Suspension parts	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Parking assist ECU initialization	Panoramic View Monitor System
		Advanced Park
Tires	Initialization*1*2 Tire Position Identification*1*2	Tire Pressure Warning System	Refer to Procedures Necessary When Replacing Parts (for Tire Pressure Warning System)
	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Parking assist ECU initialization*3	Panoramic View Monitor System
		Advanced Park
Steering gear assembly*4 No. 2 steering intermediate shaft assembly*4	End position initial setting	-
Front bumper assembly*	Front television camera view adjustment	Panoramic View Monitor System
		Advanced Park

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	ALIGN FRONT WHEELS FACING STRAIGHT AHEAD	-		-	-
2	SECURE STEERING WHEEL	-		-	-
3	COLUMN HOLE COVER SILENCER SHEET	45259A	-	-	-
4	NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY	45260		-	-
5	FRONT WHEELS	-	-	-	-

Procedure		Part Name Code
6	FRONT WHEEL OPENING EXTENSION PAD LH	53852B	-	-	-
7	FRONT WHEEL OPENING EXTENSION PAD RH	53851D	-	-	-
8	CENTER ENGINE UNDER COVER	51451A	-	-	-
9	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
10	REAR ENGINE UNDER COVER LH	51444A	-	-	-
11	REAR ENGINE UNDER COVER RH	51443C	-	-	-

Procedure		Part Name Code
12	FRONT BUMPER ASSEMBLY	-	-	-	-

Procedure		Part Name Code
13	FRONT BUMPER LOWER ABSORBER	52618	-	-	-
14	NO. 2 FRONT BUMPER REINFORCEMENT	52132A	-	-	-
15	FRONT BUMPER EXTENSION SUB-ASSEMBLY LH	52103A	-	-	-
16	FRONT BUMPER EXTENSION SUB-ASSEMBLY RH	52102B	-	-	-

Procedure		Part Name Code
17	FRONT STABILIZER LINK ASSEMBLY LH	48810		-	-
18	FRONT STABILIZER LINK ASSEMBLY RH	48820B	-	-	-
19	TIE ROD END SUB-ASSEMBLY LH	45047		-	-
20	TIE ROD END SUB-ASSEMBLY RH	45046	-	-	-
21	FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH	48069	-	-	-
22	FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH	48068	-	-	-
23	NO. 2 CROSSMEMBER GUSSET LH	51322	-	-	-
24	NO. 2 CROSSMEMBER GUSSET RH	51321	-	-	-
25	NO. 2 ENGINE UNDER COVER	51442	-	-	-
26	WIRE HARNESS CLAMP BRACKET	-	-	-	-

*1	COTTER PIN	-	-
●	Non-reusable part	-	-

Procedure		Part Name Code
27	ENGINE MOVING CONTROL ROD	12363A		-	-
28	FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY	51201		-	-

*1

CENTER RADIATOR SUPPORT LH

*2

CENTER RADIATOR SUPPORT RH

Procedure		Part Name Code
29	ENGINE MOVING CONTROL ROD	12363A	-	-	-
30	FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH	48069		-	-
31	FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH	48068	-	-	-
32	STEERING LINK ASSEMBLY	-		-	-
33	FRONT STABILIZER BAR	48811	-	-	-

●

Non-reusable part

-

-

PROCEDURE

1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

2. SECURE STEERING WHEEL

(1) Secure the steering wheel with the seat belt in order to prevent rotation.

HINT:

This operation is useful to prevent damage to the spiral cable.

3. REMOVE COLUMN HOLE COVER SILENCER SHEET

Click here

4. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

5. REMOVE FRONT WHEELS

Click here

6. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

7. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

8. REMOVE CENTER ENGINE UNDER COVER

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

9. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

10. REMOVE REAR ENGINE UNDER COVER LH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

11. REMOVE REAR ENGINE UNDER COVER RH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

12. REMOVE FRONT BUMPER ASSEMBLY

Click here

13. REMOVE FRONT BUMPER LOWER ABSORBER

Click here

14. REMOVE NO. 2 FRONT BUMPER REINFORCEMENT

Click here

15. REMOVE FRONT BUMPER EXTENSION SUB-ASSEMBLY LH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

16. REMOVE FRONT BUMPER EXTENSION SUB-ASSEMBLY RH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

17. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

(1) Remove the nut and separate the front stabilizer link assembly LH from the front stabilizer bar.

NOTICE:

Do not damage the boot of the ball joint.

HINT:

If the ball joint turns together with the nut, use a 6 mm hexagon socket wrench to hold the stud bolt.

18. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

(a) Perform the same procedure as for the LH side.

19. SEPARATE TIE ROD END SUB-ASSEMBLY LH

*a	String	*b	Center Nut
*c	Place wrench here	*d	Molybdenum Grease Application Area
	Turn	-	-

(1) Remove the cotter pin and nut.

(2) Install SST to the tie rod end sub-assembly LH as shown in the illustration.

SST: 09960-20010

09961-02060

NOTICE:

Make sure that the lower ends of the tie rod end sub-assembly LH and SST are aligned.

(3) Using SST, separate the tie rod end sub-assembly LH from the steering knuckle LH as shown in the illustration.

SST: 09960-20010

09961-02010

09961-02060

CAUTION:

Apply molybdenum grease to the threads and end of the SST bolt.

20. SEPARATE TIE ROD END SUB-ASSEMBLY RH

(a) Perform the same procedure as for the LH side.

21. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

Click here

22. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

(a) Perform the same procedure as for the LH side.

23. REMOVE NO. 2 CROSSMEMBER GUSSET LH

Remove in this Direction

-

-

24. REMOVE NO. 2 CROSSMEMBER GUSSET RH

(a) Perform the same procedure as for the LH side.

25. REMOVE NO. 2 ENGINE UNDER COVER

26. DISCONNECT WIRE HARNESS CLAMP BRACKET

27. DISCONNECT ENGINE MOVING CONTROL ROD

*a	Transmission Jack	*b	Wooden Block
	Front of the Toyota Prius Vehicle		Wooden block placement location

(1) Using a transmission jack and a wooden block, support the engine assembly with transaxle.

(2) Remove the bolt and separate the engine moving control rod.

28. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

*a	Engine Lifter	*b	Attachment
	Attachment placement location	-	-

(1) Support the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.

NOTICE:

Use attachments to keep the front suspension crossmember sub-assembly level.

(2) Remove the 8 bolts, center radiator support LH, center radiator support RH and front suspension crossmember sub-assembly from the Toyota Prius vehicle.

(3) Slowly lower the front suspension crossmember sub-assembly.

29. REMOVE ENGINE MOVING CONTROL ROD

30. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

NOTICE: Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut secured.

31. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

(a) Perform the same procedure as for the LH side.

32. REMOVE STEERING LINK ASSEMBLY

Click here

33. REMOVE FRONT STABILIZER BAR

Click here

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	FRONT STABILIZER BAR	48811		-	-
2	STEERING LINK ASSEMBLY	-		-	-
3	TEMPORARILY INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH	48069		-	-
4	TEMPORARILY INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH	48068	-	-	-
5	INSTALL ENGINE MOVING CONTROL ROD	12363A	-	-	-

	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
●	Non-reusable part	-	-

Procedure		Part Name Code
6	FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY	51201		-	-
7	CONNECT ENGINE MOVING CONTROL ROD	12363A	-	-	-

*1	CENTER RADIATOR SUPPORT LH	*2	CENTER RADIATOR SUPPORT RH
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
8	WIRE HARNESS CLAMP BRACKET	-	-	-	-
9	NO. 2 ENGINE UNDER COVER	51442	-	-	-
10	NO. 2 CROSSMEMBER GUSSET LH	51322	-	-	-
11	NO. 2 CROSSMEMBER GUSSET RH	51321	-	-	-
12	CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH	48069	-	-	-
13	CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH	48068	-	-	-
14	TIE ROD END SUB-ASSEMBLY LH	45047		-	-
15	TIE ROD END SUB-ASSEMBLY RH	45046	-	-	-
16	FRONT STABILIZER LINK ASSEMBLY LH	48810		-	-
17	FRONT STABILIZER LINK ASSEMBLY RH	48820B	-	-	-

*1	COTTER PIN	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
●	Non-reusable part	-	-

Procedure		Part Name Code
18	FRONT BUMPER EXTENSION SUB-ASSEMBLY LH	52103A	-	-	-
19	FRONT BUMPER EXTENSION SUB-ASSEMBLY RH	52102B	-	-	-
20	NO. 2 FRONT BUMPER REINFORCEMENT	52132A	-	-	-
21	FRONT BUMPER LOWER ABSORBER	52618	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

Procedure		Part Name Code
22	FRONT BUMPER ASSEMBLY	-	-	-	-

Procedure		Part Name Code
23	REAR ENGINE UNDER COVER LH	51444A	-	-	-
24	REAR ENGINE UNDER COVER RH	51443C	-	-	-
25	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
26	CENTER ENGINE UNDER COVER	51451A	-	-	-
27	FRONT WHEEL OPENING EXTENSION PAD LH	53852B	-	-	-
28	FRONT WHEEL OPENING EXTENSION PAD RH	53851D	-	-	-
29	FRONT WHEELS	-	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

Procedure		Part Name Code
30	NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY	45260		-	-
31	COLUMN HOLE COVER SILENCER SHEET	45259A	-	-	-
32	STABILIZE SUSPENSION	-		-	-
33	FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH	48069		-	-
34	FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH	48068		-	-
35	INSPECT AND ADJUST FRONT WHEEL ALIGNMENT	-	-	-
36	PERFORM INITIALIZATION	-	-	-

Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

*

For use with SST

PROCEDURE

1. INSTALL FRONT STABILIZER BAR

Click here

2. INSTALL STEERING LINK ASSEMBLY

Click here

3. TEMPORARILY INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

NOTICE: Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

4. TEMPORARILY INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

5. INSTALL ENGINE MOVING CONTROL ROD

Torque:

200 N·m {2039 kgf·cm, 148 ft·lbf}

6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

*a	Engine Lifter	*b	Attachment
	Attachment placement location	-	-

(1) Slowly jack up the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.

(2) Install the front suspension crossmember sub-assembly with the 8 bolts, center radiator support LH and center radiator support RH.

Torque:

Bolt (A) :

141 N·m {1438 kgf·cm, 104 ft·lbf}

Bolt (B) :

32 N·m {326 kgf·cm, 24 ft·lbf}

Bolt (C) :

12 N·m {122 kgf·cm, 9 ft·lbf}

7. CONNECT ENGINE MOVING CONTROL ROD

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

8. CONNECT WIRE HARNESS CLAMP BRACKET

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

9. INSTALL NO. 2 ENGINE UNDER COVER

Torque:

48.5 N·m {495 kgf·cm, 36 ft·lbf}

10. INSTALL NO. 2 CROSSMEMBER GUSSET LH

Install in this Direction

-

-

Torque:

Bolt (A) :

72 N·m {734 kgf·cm, 53 ft·lbf}

Bolt (B) :

7.5 N·m {76 kgf·cm, 66 in·lbf}

11. INSTALL NO. 2 CROSSMEMBER GUSSET RH

12. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

Click here

13. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

14. CONNECT TIE ROD END SUB-ASSEMBLY LH

(1) Connect the tie rod end sub-assembly LH to the steering knuckle LH with the nut.

Torque:

49 N·m {500 kgf·cm, 36 ft·lbf}

(2) Install a new cotter pin.

15. CONNECT TIE ROD END SUB-ASSEMBLY RH

16. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

Torque:

74 N·m {755 kgf·cm, 55 ft·lbf}

HINT:

If the ball joint turns together with the nut, use a 6 mm hexagon socket wrench to hold the stud bolt.

17. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

18. INSTALL FRONT BUMPER EXTENSION SUB-ASSEMBLY LH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

19. INSTALL FRONT BUMPER EXTENSION SUB-ASSEMBLY RH

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

20. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT

Click here

21. INSTALL FRONT BUMPER LOWER ABSORBER

22. INSTALL FRONT BUMPER ASSEMBLY

Click here

23. INSTALL REAR ENGINE UNDER COVER LH

24. INSTALL REAR ENGINE UNDER COVER RH

25. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

26. INSTALL CENTER ENGINE UNDER COVER

for M20A-FXS HEV Model: Click here

for M20A-FXS PHEV Model: Click here

for 2ZR-FXE: Click here

27. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

28. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

29. INSTALL FRONT WHEELS

Click here

30. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

31. INSTALL COLUMN HOLE COVER SILENCER SHEET

Click here

32. STABILIZE SUSPENSION

(1) Press down on the Toyota Prius vehicle several times to stabilize the suspension.

33. FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

(1) Fully tighten the bolt (A).

Torque:

240 N·m {2447 kgf·cm, 177 ft·lbf}

(2) Fully tighten the bolt (B).

Torque:

125 N·m {1275 kgf·cm, 92 ft·lbf}

NOTICE:

Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

34. FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

*a

Torque Wrench Fulcrum Length

-

-

(1) Using SST, fully tighten the bolt (A).

Torque:

Specified tightening torque :

240 N·m {2447 kgf·cm, 177 ft·lbf}

SST: 09729-00220

(b) Fully tighten the bolt (B).

Torque:

125 N·m {1275 kgf·cm, 92 ft·lbf}

NOTICE:

Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

35. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here

36. PERFORM INITIALIZATION

Parking Assist Monitor System
Panoramic View Monitor System
Advanced Park