Toyota Prius: Brake Booster

• 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 brake booster with master cylinder 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
Removal/installation/replacement of brake booster with master cylinder assembly	Update ECU security key (Only necessary after replacement)	Toyota Prius Vehicle Control History (RoB) are stored
	Bleed air Perform "Calibration" (Only necessary after replacement)	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	for Bleeding: for Calibration:

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when Toyota Prius vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
*1: w/o Power Back Door System *2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	for HEV Model: After the ignition switch is turned to ON, the servo motor standard position is recognized. for PHEV Model: After the ignition switch is turned to ON, the servo motor and expansion valve standard position is recognized.	-

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
2	WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY	-	-	-	-
3	WATER GUARD PLATE	55734D	-	-	-
4	OUTER COWL TOP PANEL SUB-ASSEMBLY	55701J	-	-	-

*A

for M20A-FXS

*B

for 2ZR-FXE

Procedure		Part Name Code
5	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
6	DRAIN BRAKE FLUID	-	-		-
7	ENGINE ROOM MAIN WIRE	82111		-	-
8	BRAKE LINE	-		-	-
9	BRAKE PEDAL RETURN SPRING	47101A	-	-	-
10	PUSH ROD PIN	47264A	-	-	-
11	BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY	47210L		-	-
12	BRAKE MASTER CYLINDER GASKET	44785D	-	-	-

●

Non-reusable part

-

-

Procedure		Part Name Code
13	MASTER CYLINDER PUSH ROD CLEVIS	47264	-	-	-
14	MASTER CYLINDER PUSH ROD NUT	47262	-	-	-

PROCEDURE

1. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

for M20A-FXS: Click here

for 2ZR-FXE: Click here

2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

3. REMOVE WATER GUARD PLATE

Click here

4. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

5. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

6. DRAIN BRAKE FLUID

NOTICE: If brake fluid leaks onto any painted surface, immediately wash it off.

7. SEPARATE ENGINE ROOM MAIN WIRE

NOTICE: When disconnecting a wire harness of any component connected to the supply power of the integrated capacitor (integration control supply) or when removing the integrated capacitor (integration control supply), make sure to wait 5 minutes or more after turning the ignition switch off for self-diagnosis to complete and the voltage of the integrated capacitor (integration control supply) to discharge.

*a	Retainer	*b	Lock Lever
	Draw the retainer in this Direction		Raise the lock lever in this Direction

(1) Disconnect the connector and disengage the clamp.

(2) Draw the retainer.

(3) Disengage the claw and raise the lock lever to disconnect the connector as shown in the illustration.

NOTICE:

Be careful not to allow any brake fluid to enter the connector.

(4) Disengage the clamp to separate the engine room main wire.

8. DISCONNECT BRAKE LINE

NOTICE: Do not kink or damage the brake lines. Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

(1) Using a union nut wrench, disconnect the 2 brake lines from the brake booster with master cylinder assembly.

9. REMOVE BRAKE PEDAL RETURN SPRING

Click here

10. REMOVE PUSH ROD PIN

Click here

11. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

NOTICE: Do not apply excessive force to the brake lines. Do not drop the brake booster with master cylinder assembly when carrying it. Be careful not to allow any brake fluid to enter the connector.

12. REMOVE BRAKE MASTER CYLINDER GASKET

13. REMOVE MASTER CYLINDER PUSH ROD CLEVIS

HINT:

Perform this procedure only when replacement of the master cylinder push rod clevis is necessary.

14. REMOVE MASTER CYLINDER PUSH ROD NUT

HINT:

Perform this procedure only when replacement of the master cylinder push rod nut is necessary.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	MASTER CYLINDER PUSH ROD NUT	47262	-	-	-
2	MASTER CYLINDER PUSH ROD CLEVIS	47264		-	-

Procedure		Part Name Code
3	BRAKE MASTER CYLINDER GASKET	44785D	-	-	-
4	BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY	47210L		-	-
5	PUSH ROD PIN	47264A		-	-
6	BRAKE PEDAL RETURN SPRING	47101A		-	-
7	BRAKE LINE	-		-	-
8	ENGINE ROOM MAIN WIRE	82111		-	-
9	INSPECT AND ADJUST BRAKE PEDAL HEIGHT	-	-	-
10	INSPECT BRAKE PEDAL FREE PLAY	-	-	-
11	CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
12	UPDATE ECU SECURITY KEY	-	-	-
13	INSPECT AND ADJUST BRAKE PEDAL STROKE SENSOR	-	-	-
14	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
15	BLEED BRAKE SYSTEM	-	-	-

	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 a union nut wrench
●	Non-reusable part		Lithium soap base glycol grease

Procedure		Part Name Code
16	OUTER COWL TOP PANEL SUB-ASSEMBLY	55701J	-	-	-
17	WATER GUARD PLATE	55734D	-	-	-
18	WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY	-	-	-	-
19	PERFORM BRAKE SYSTEM CALIBRATION	-	-	-
20	INSPECT BRAKE PEDAL RESERVE DISTANCE	-	-	-
21	CHECK AND CLEAR DTC	-	-	-	-
22	PERFORM INITIALIZATION AND CALIBRATION	-	-	-

*A	for M20A-FXS	*B	for 2ZR-FXE
	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

1. INSTALL MASTER CYLINDER PUSH ROD NUT

HINT:

Perform this procedure only when replacement of the master cylinder push rod nut is necessary.

2. INSTALL MASTER CYLINDER PUSH ROD CLEVIS

HINT:

Perform this procedure only when replacement of the master cylinder push rod clevis is necessary.

NOTICE: Fully tighten the master cylinder push rod nut when adjusting the brake pedal height.

3. INSTALL BRAKE MASTER CYLINDER GASKET

4. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(1) Install the brake booster with master cylinder assembly with the 4 nuts in the order shown in the illustration.

Torque:

12.7 N·m {130 kgf·cm, 9 ft·lbf}

5. INSTALL PUSH ROD PIN

Click here

6. INSTALL BRAKE PEDAL RETURN SPRING

Click here

7. CONNECT BRAKE LINE

*a

Union Nut Wrench

*b

Torque Wrench Fulcrum Length

(1) Using a union nut wrench, connect the 2 brake lines to the brake booster with master cylinder assembly.

Torque:

Specified tightening torque :

19.5 N·m {199 kgf·cm, 14 ft·lbf}

8. INSTALL ENGINE ROOM MAIN WIRE

NOTICE: Make sure that the connector is locked securely. Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.

9. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

Click here

10. INSPECT BRAKE PEDAL FREE PLAY

Click here

11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for M20A-FXS: Click here

for 2ZR-FXE: Click here

12. UPDATE ECU SECURITY KEY

HINT:

Perform this procedure only when replacement of the brake booster with master cylinder assembly is necessary.

Click here

13. INSPECT AND ADJUST BRAKE PEDAL STROKE SENSOR

Click here

14. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

15. BLEED BRAKE SYSTEM

Click here

16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

17. INSTALL WATER GUARD PLATE

18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

19. PERFORM BRAKE SYSTEM CALIBRATION

Click here

20. INSPECT BRAKE PEDAL RESERVE DISTANCE

Click here

21. CHECK AND CLEAR DTC

22. PERFORM INITIALIZATION AND CALIBRATION

Click here