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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information >> BRAKE PEDAL (for Gasoline Model) >> Installation [10/2022 - ] >> Procedure

Installation [10/2022 - ]: Procedure

  1. INSTALL BRAKE PEDAL PAD 
    1. Install the brake pedal pad to the brake pedal support assembly.

      HINT: 

      Installation is easier after applying a small amount of soapy water.

  2. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER 
    1. Engage the 2 claws to install the stop light switch mounting adjuster.
  3. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring to the brake pedal support assembly.
      GTY924630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Up
      Front of the Vehicle
      NOTE:

      Attach the bottom part of the brake pedal return spring first, making sure that the open part of the hook is facing the front of the vehicle. Attach the top part of the brake pedal return spring second, making sure that the open part of the hook is facing the rear of the vehicle.

  4. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY 
    1. Push the brake booster with master cylinder toward the engine compartment, and install the brake pedal support assembly while avoiding the stud bolts of the brake booster with master cylinder and brake booster support base.
      NOTE:
      • Be careful not to deform the bracket of the instrument panel reinforcement assembly.
      • Do not apply excessive force to the brake lines.
      • Do not apply excessive force to the wire harness.
    2. Return the brake booster with master cylinder to its original position.
    3. Install the brake pedal support assembly with the 4 nuts.

      Torque: 12.7 N.m (130 kgf/cm, 9 ft.lbf) 

    4. Install the brake pedal support assembly to the instrument panel reinforcement assembly with the bolt.

      Torque: 15 N.m (153 kgf/cm, 11 ft.lbf) 

    5. Engage the 2 clamps to install the wire harness to the brake pedal support assembly.
    6. Connect the connector.
  5. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the push rod pin.
      GTY759014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium Soap Base Glycol Grease
    2. Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the push rod pin, and install a new clip as shown in the illustration.
      GTY916662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The push rod pin can be installed in either direction.

  6. INSTALL STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL ENGINE STOP AND START SOLENOID FILTER (w/ Stop and Start System) 

    Refer to PROCEDURE - Step 1

  8. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to PROCEDURE - Step 1 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 1 [11/2023 - ]

  9. INSTALL NO. 1 SWITCH HOLE BASE 

    Refer to PROCEDURE - Step 25

  10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  11. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 27

  12. CONNECT BRAKE LINE 
    1. Using a union nut wrench, connect the brake line to the brake master cylinder sub-assembly.
      GTY1111501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Specified tightening torque 

      Torque: 19.5 N.m (199 kgf/cm, 14 ft.lbf) 

      NOTE:
      • Do not kink or damage the brake line.
      • Do not allow the brake line to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [12/2019 - 11/2023] , or refer to PRECAUTION [11/2023 - ]

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.4 N.m (177 kgf/cm, 13 ft.lbf)

    2. Using a union nut wrench, connect the brake line to the brake master cylinder sub-assembly.
      GTY1115070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Specified tightening torque 

      Torque: 19.5 N.m (199 kgf/cm, 14 ft.lbf) 

      NOTE:
      • Do not kink or damage the brake line.
      • Do not allow the brake line to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [12/2019 - 11/2023] , or refer to PRECAUTION [11/2023 - ]

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.4 N.m (177 kgf/cm, 13 ft.lbf)

  13. CONNECT CONNECTOR 

    See step  3

  14. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [10/2022 - ] 

  15. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [10/2022 - ] 

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

    Refer to PROCEDURE - Step 28

  17. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 49

  18. INSTALL FRONT DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 50

  19. INSPECT SRS WARNING LIGHT 

    Refer to OPERATION CHECK [10/2022 - 11/2023] , or refer to OPERATION CHECK [11/2023 - ]

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