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HOMESERVICE MANUALSTOYOTA2018PRIUS TWO ECOREPAIR AND DIAGNOSIS (SINGLE PAGE)BRAKESANTI-LOCK BRAKESBRAKE CONTROL SYSTEM - SERVICE INFORMATIONBRAKE ACTUATORREMOVAL [11/2015 - 12/2018]PROCEDURE
2018 Toyota Prius Two Eco

Removal [11/2015 - 12/2018]: Procedure

2018 Toyota Prius Two EcoSECTION Procedure
  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2015 - 11/2017] , or refer to PRECAUTION [11/2017 - 12/2018]

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 3

  5. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 4

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 5

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  8. PERFORM ACCUMULATOR PRESSURE ZERO DOWN 

    Refer to PROCEDURE - Step 7

  9. DRAIN BRAKE FLUID 
    NOTE:

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

  10. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 13 [08/2016 - 12/2018]

  11. SEPARATE SUCTION PIPE SUB-ASSEMBLY 
    1. Disengage the 2 clamps to separate the suction pipe sub-assembly.
      GTY581474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and rotate the hook connector.
      GTY581476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the suction pipe sub-assembly from the air conditioning unit assembly.
    4. Remove the O-ring from the suction pipe sub-assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  12. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Disengage the 2 clamps to separate the air conditioner tube and accessory assembly.
      GTY581473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the air conditioner tube and accessory assembly from the air conditioning unit assembly.
      GTY581471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the air conditioner tube and accessory assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  13. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Release the lock lever and disconnect the connector from the brake booster pump assembly as shown in the illustration.
      GTY552340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release the lock lever
      Disconnect the connector
      NOTE:

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

    2. Release the lock lever and disconnect the connector from the brake actuator assembly as shown in the illustration.
      GTY569574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release the lock lever
      Disconnect the connector
      NOTE:

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

    3. Disengage the clamp and separate the engine room main wire.
  14. SEPARATE NO. 1 BRAKE ACTUATOR HOSE 
    1. Slide the clip and disconnect the No. 1 brake actuator hose from the No. 1 brake actuator tube.
      GTY581466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the No. 1 brake actuator hose from the brake actuator hose clamp.
      GTY581452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SEPARATE BRAKE LINE 
    1. Use tags or make a memo to identify the places to reconnect the brake lines.
      GTY593430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Booster with Master Cylinder Assembly
      *b From 2nd Chamber of Brake Booster with Master Cylinder Assembly
      *c To Front Wheel Cylinder Assembly LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH
      *f To Front Wheel Cylinder Assembly RH
    2. Using a union nut wrench, disconnect the 6 brake lines from the brake actuator assembly.
      GTY607105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. SEPARATE ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE 
    1. Using a union nut wrench, disconnect the accumulator to brake master cylinder tube from the brake booster pump assembly.
      GTY581531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt to separate the accumulator to brake master cylinder tube.
  17. SEPARATE BRAKE BOOSTER PUMP ASSEMBLY 
    1. Disengage the claw and clamp to separate the brake booster pump assembly wire harness from the brake actuator bracket assembly.
      GTY607124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut to separate the brake booster pump assembly from the brake actuator bracket assembly.
      GTY545429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Move in this Direction

      HINT: 

      Move the brake booster pump assembly to the position where the lower bolt of the brake actuator assembly can be removed.

  18. REMOVE BRAKE ACTUATOR ASSEMBLY 
    1. Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.
      GTY581742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not hold the brake actuator assembly by the connector.
      • Do not apply excessive force to the brake lines or refrigerant lines.
      • Be careful not to allow any brake fluid to enter the connector.
      • Do not drop the brake actuator assembly when carrying it.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.