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Home >> Toyota >> 2012 >> Prius L4-1.8L (2ZR-FXE) Hybrid >> Repair and Diagnosis >> Steering and Suspension >> Suspension >> Axle Beam >> Service and Repair >> Installation

Installation





REAR SUSPENSION: REAR AXLE BEAM: INSTALLATION

1. INSTALL REAR AXLE CARRIER BUSHING LH

(a) Align the arrow mark on a new rear axle carrier bushing LH with the matchmark on the rear axle beam assembly and temporarily install the rear axle carrier bushing LH to the rear axle beam assembly. (If the rear axle beam assembly is reused.)





Text in Illustration





NOTICE:
Be sure to install the rear axle carrier bushing in the same direction as it was before removal.

The rear axle carrier bushing has to be installed in a specific direction.

(b) Temporarily install the new rear axle carrier bushing LH as shown in the illustration.





Text in Illustration





NOTICE:
Be sure to install the rear axle carrier bushing in the same direction as it was before removal.

The rear axle carrier bushing has to be installed in a specific direction.

(c) Using SST, install the rear axle carrier bushing LH to the rear axle beam assembly.





Text in Illustration





NOTICE:
* Do not damage the rubber portion when installing the rear axle carrier bushing.
* Apply grease to the threads and tip of the SST center bolt before use.

SST : 09710-30012

09710-04101

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04020

09955-04051

09957-04010

09958-04011

SST : 09950-60010

09951-00620

2. INSTALL REAR AXLE CARRIER BUSHING RH

HINT
Perform the same procedure as for the LH side.

3. TEMPORARILY TIGHTEN REAR AXLE BEAM ASSEMBLY

(a) Slowly jack up the rear axle beam assembly with a jack using 2 wooden blocks and 2 attachments or equivalent tools and temporarily install the rear axle beam assembly to the body with the 2 bolts (B).





Text in Illustration





NOTICE:
Make sure to secure the rear axle beam assembly to prevent it from dropping.

(b) Temporarily tighten the rear axle beam assembly to the rear shock absorber assemblies LH and RH with the 2 bolts (A) and 2 nuts.

NOTICE:
Since the stopper nuts are used, turn the bolts.

HINT
Insert the bolts with the threaded end facing the outside of the vehicle.

4. INSTALL REAR UPPER COIL SPRING INSULATOR LH Installation

5. INSTALL REAR UPPER COIL SPRING INSULATOR RH

HINT
Perform the same procedure as for the LH side.

6. INSTALL REAR LOWER COIL SPRING INSULATOR LH

7. INSTALL REAR LOWER COIL SPRING INSULATOR RH

8. INSTALL REAR COIL SPRING LH Installation

9. INSTALL REAR COIL SPRING RH

HINT
Perform the same procedure as for the LH side.

10. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY RH (w/ Height Control Sensor) Installation

11. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH Installation

12. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

13. INSTALL REAR NO. 4 BRAKE TUBE

(a) Install the rear No. 4 brake tube to the rear axle beam assembly with the nut.





Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

14. INSTALL REAR NO. 3 BRAKE TUBE

HINT
Perform the same procedure as for the rear No. 4 brake tube.

15. CONNECT REAR BRAKE TUBE FLEXIBLE HOSE

(a) for LH Side





Text in Illustration





(1) Install the rear brake tube flexible hose with the bolt.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(b) for RH Side

(1) Install the rear brake tube flexible hose with a new clip.

NOTICE:
Install the clip as far as it will go.

(c) Using a union nut wrench, connect the 2 brake lines to the rear brake tube flexible hose.

Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
* Do not bend or damage the brake line.
* Do not allow any foreign matter such as dirt and dust to enter the brake line from the connecting points.
* Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench Service Precautions.

16. INSTALL REAR DISC (for LH Side) Installation

17. INSTALL REAR DISC (for RH Side)

HINT
Perform the same procedure as for the LH side.

18. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH

(a) Install the rear disc brake caliper assembly LH with rear flexible hose LH with the 2 bolts.





Torque : 57 Nm (585 kgf-cm, 42 ft-lbf)

(b) Connect the rear flexible hose LH to the rear axle beam assembly with a new clip.





NOTICE:
Install the clip as far as it will go.

(c) Using a union nut wrench, connect the brake line to the rear flexible hose LH while holding the rear flexible hose LH with a wrench.





Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
* Do not bend or damage the brake line.
* Do not allow any foreign matter such as dirt and dust to enter the brake line from the connecting points.
* Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench Service Precautions.

19. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

20. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY

(a) Install the No. 3 parking brake cable assembly to the rear axle beam assembly with the bolt.





Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

21. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY

HINT
Perform the same procedure as for the No. 3 parking brake cable assembly.

22. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY Installation

23. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

HINT
Perform the same procedure as for the LH side.

24. INSTALL REAR SPEED SENSOR WIRE (for LH Side) Installation

25. INSTALL REAR SPEED SENSOR WIRE (for RH Side)

HINT
Perform the same procedure as for the LH side.

26. CONNECT REAR SPEED SENSOR WIRE (for LH Side) Installation

27. CONNECT REAR SPEED SENSOR WIRE (for RH Side)

HINT
Perform the same procedure as for the LH side.

28. INSTALL REAR SUSPENSION BRACE SUB-ASSEMBLY

(a) Install the rear suspension brace sub-assembly with the 4 bolts and clip.





Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

29. INSTALL REAR FLOOR SIDE MEMBER COVER LH (w/ Floor Under Cover)

(a) Install the rear floor side member cover LH with the nut and 2 bolts.





30. INSTALL REAR FLOOR SIDE MEMBER COVER RH (w/ Floor Under Cover)

(a) Engage the clip to temporarily install the rear floor side member cover RH.





(b) Install the rear floor side member cover RH with the 3 bolts.

31. ADJUST PARKING BRAKE

Adjustments

32. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY Installation

33. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH Installation

34. INSTALL FRONT DOOR SCUFF PLATE LH Installation

35. FILL RESERVOIR WITH BRAKE FLUID

36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

37. INSTALL REAR NO. 3 FLOOR BOARD Installation

38. INSTALL REAR DECK FLOOR BOX Installation

39. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) Installation

40. BLEED BRAKE LINE Service and Repair

41. INSTALL REAR WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

42. STABILIZE SUSPENSION Installation

43. FULLY TIGHTEN REAR AXLE BEAM ASSEMBLY Installation

44. INSTALL REAR WHEEL HOUSE LINER LH (w/ Wheel House Liner) Installation

45. INSTALL REAR WHEEL HOUSE LINER RH (w/ Wheel House Liner)

HINT
Perform the same procedure as for the LH side.

46. INSPECT REAR WHEEL ALIGNMENT

Rear Wheel Alignment

47. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

48. PERFORM YAW RATE AND ACCELERATION SENSOR CALIBRATION

Calibration

49. CHECK FOR SPEED SENSOR SIGNAL

Test Mode Procedure

50. PERFORM INITIALIZATION (w/ Height Control Sensor)

NOTICE:
Some systems need to be initialized after the rear height control sensor sub-assembly RH is replaced Repair Instruction - Initialization.

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