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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information >> BRAKE BOOSTER (for HV Model) >> Removal [10/2022 - 11/2023] >> Procedure

Removal [10/2022 - 11/2023]: Procedure

  1. PERFORM ACCUMULATOR PRESSURE ZERO DOWN 
    1. Using the GTS, perform the accumulator pressure zero down operation.
      1. Select "Motor Deactivate" on the "ECB Utility" screen.

        Chassis > Brake/EPB > Utility 

        Tester Display
        ECB Utility
      2. Perform "Motor Deactivate" according to the display on the GTS.
      3. Select "ECB Deactivate" on the "ECB Utility" screen.

        Chassis > Brake/EPB > Utility 

        Tester Display
        ECB Utility
      4. Perform "ECB Deactivate" according to the display on the GTS.
      5. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

        HINT: 

        A buzzer may sound due to low accumulator pressure. As this is not a malfunction, continue the procedure.

      6. Check that the brake pedal is firm.
        NOTE:

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down operation is not complete.

      7. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Refer to REMOVAL [10/2022 - 11/2023]

    2. When the accumulator pressure zero down could not be performed using the GTS.
      NOTE:

      If DTCs are output, the accumulator pressure zero down operation may not be complete. In this case, perform the following procedure.

      1. With the ignition switch off, disconnect the brake master cylinder with pump assembly connector.
        GTY917950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

      2. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.
      3. Check that the brake pedal is firm.
        NOTE:

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down operation is not complete.

      4. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Refer to REMOVAL [10/2022 - 11/2023]

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  3. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 3

  4. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  5. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 5

  6. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  7. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  8. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  9. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  10. REMOVE ECM 

    Refer to REMOVAL [10/2022 - 11/2023]

  11. DRAIN BRAKE FLUID 
    NOTE:

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

  12. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Disconnect the connector from the brake master cylinder with pump assembly.
      GTY917950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the lock lever and disconnect the connector from the brake master cylinder with pump assembly.
      GTY933906Courtesy 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 to separate the engine room main wire from the brake master cylinder with pump assembly.
    4. Remove the bolt to separate the engine room main wire from the vehicle body.
      GTY916630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT RESERVOIR HOSE 
    1. Slide the 2 clips and disconnect the 2 reservoir hoses from the brake master cylinder with pump assembly.
      GTY917948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT BRAKE LINE 
    1. Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder with pump assembly.
      GTY917947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 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.
  15. REMOVE FRONT DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 9

  16. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 3

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

    Refer to PROCEDURE - Step 17

  18. DISCONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 18

  19. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 19

  20. REMOVE NO. 1 SWITCH HOLE BASE 

    Refer to PROCEDURE - Step 20

  21. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to PROCEDURE - Step 10

  22. REMOVE VEHICLE APPROACHING SPEAKER CONTROLLER 

    Refer to PROCEDURE - Step 2

  23. REMOVE STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 4

  24. REMOVE BRAKE PEDAL RETURN SPRING 
    1. Remove the brake pedal return spring from the brake pedal support assembly.
      GTY917924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE PUSH ROD PIN 
    1. Remove the clip and push rod pin.
      GTY917967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE BRAKE MASTER CYLINDER WITH PUMP ASSEMBLY 
    1. Remove the 4 nuts and brake master cylinder with pump assembly.
      GTY917966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the brake lines.
      • Be careful not to allow any brake fluid to enter the connector.
  27. REMOVE BRAKE BOOSTER GASKET 
  28. REMOVE NO. 2 RESERVOIR HOSE 
    1. Slide the 2 clips and remove the No. 2 reservoir hose.
      GTY943777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 RESERVOIR HOSE 
    1. Slide the 2 clips and remove the No. 1 reservoir hose.
      GTY917963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 1 BRAKE ACTUATOR TUBE 
    1. Using a union nut wrench, remove the No. 1 brake actuator tube.
      GTY917961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the brake line.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.
  31. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY 

    See step  3

  32. REMOVE NO. 1 WIRE CLAMP BRACKET 
    1. Using a 5 mm long hexagon socket wrench, remove the bolt and No. 1 wire clamp bracket.
      GTY917931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 2 WIRE CLAMP BRACKET 
    1. Using a 5 mm long hexagon socket wrench, remove the bolt and No. 2 wire clamp bracket.
      GTY943769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE NO. 3 BRAKE POWER SUPPLY BRACKET 
    1. Using a 5 mm long hexagon socket wrench, remove the 2 bolts and No. 3 brake power supply bracket.
      GTY942488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE NO. 2 BRAKE POWER SUPPLY BRACKET 
    1. Using a 5 mm long hexagon socket wrench, remove the 2 bolts and No. 2 brake power supply bracket.
      GTY917930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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