OEM 2003 Toyota Prius Brake Booster

2003 Toyota Prius Parts Questions & Experts Answers

• Q: How to service and repair the hydraulic brake booster on 2003 Toyota Prius?

  A: One should use Special Service Tool: 09023-00100 to uninstall the brake actuator tube at 15 Nm torque before removing 2 clips and suction hose. The 4 brake power supply bracket No. 3 bolts need to be removed at 7.8 Nm torque setting (80 kgf-cm or 69 inch lbs.). After applying 7.8 Nm torque to the brake booster pump bracket No. 1 and its clamp and two bolts, remove the pressure switch assembly followed by removing three bolts from brake booster pump bracket No. 2 using the same torque setting. Start by removing 2 screws from the booster pump wire harness before disconnecting all connectors from the connector bracket and removing the bolt and clamp and connector bracket at 7.8 Nm (80 kgf-cm, 69 inch lbs.). Guard the brake power supply brackets No. 1 and No. 2 before removing their 4 bolts while using the original torque value. You must place the booster pump inside a vise equipped with a protective cloth before separating the accumulator through removal of 2 washers, 3 cushions, 2 collars, and a sleeve by using Special Service Tool: 09318-12010 with torque set at 54 Nm (550 kgf-cm, 36 ft. lbs.) before continue with spring and silencer tube and O-ring removal while avoiding foreign matter entry into the pump. To inspect the pump motor operation insert the positive (+) lead from the battery to terminal 1 on the pump motor then connect the negative (-) lead to terminal 2. A worker should drain the high-pressure gas from the accumulator and then place it in a vise covered by a cloth to make slow cuts on the body using a saw while being mindful to avoid continuous cutting because gas will escape when cutting the outer body. The reversing procedure of disassembly becomes the assembly process.