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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) >> Installation [12/2019 - 11/2023] >> Procedure

Installation [12/2019 - 11/2023]: Procedure

  1. INSTALL NO. 2 BRAKE POWER SUPPLY BRACKET 
    1. Using a 5 mm long hexagon socket wrench, install the No. 2 brake power supply bracket with the 2 bolts.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

  2. INSTALL NO. 3 BRAKE POWER SUPPLY BRACKET 
    1. Using a 5 mm long hexagon socket wrench, install the No. 3 brake power supply bracket with the 2 bolts.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

  3. INSTALL NO. 2 WIRE CLAMP BRACKET 
    1. Using a 5 mm long hexagon socket wrench, install the No. 2 wire clamp bracket with the bolt.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

  4. INSTALL NO. 1 WIRE CLAMP BRACKET 
    1. Using a 5 mm long hexagon socket wrench, install the No. 1 wire clamp bracket with the bolt.

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

  5. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY 

    See step  1

  6. INSTALL NO. 1 BRAKE ACTUATOR TUBE 
    1. Using a union nut wrench, install the No. 1 brake actuator tube.
      GTY869839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Specified tightening torque 

      Torque: 15.2 N.m (155 kgf/cm, 11 ft.lbf) 

      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.

      HINT: 

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

        Refer to PRECAUTION [12/2019 - 11/2023]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.4 N.m (137 kgf/cm, 10 ft.lbf)

  7. INSTALL NO. 1 RESERVOIR HOSE 
    1. Install the No. 1 reservoir hose, and slide the 2 clips to secure it.
      GTY859668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90°
      Front of the Vehicle
      NOTE:
      • Make sure that the paint mark is facing the front of the vehicle.
      • Install the clip within the range shown in the illustration.
  8. INSTALL NO. 2 RESERVOIR HOSE 
    1. Install the No. 2 reservoir hose, and slide the 2 clips to secure it.
      GTY844498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90°
      Front of the Vehicle
      Up
      NOTE:
      • Make sure that the paint mark is facing the front of the vehicle (Upper Side).
      • Make sure that the paint mark is facing up (Lower Side).
      • Install the clip within the range shown in the illustration.
  9. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake master cylinder with pump assembly.
  10. INSTALL BRAKE MASTER CYLINDER WITH PUMP ASSEMBLY 
    1. Install the brake master cylinder with pump assembly with the 4 nuts.

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

      NOTE:
      • Do not apply excessive force to the brake lines.
      • Be careful not to allow brake fluid to enter the connector.
      • If installing a new brake master cylinder with pump assembly, do not remove the hole plugs before connecting the brake lines because the brake booster with master cylinder assembly is filled with brake fluid.
  11. 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 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.
      GTY917967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The push rod pin can be installed in either direction.

  12. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring to the brake pedal support assembly.
      GTY921134Courtesy 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.

  13. INSTALL STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  14. CONNECT BRAKE LINE 
    1. Using a union nut wrench, connect the 2 brake lines to the brake master cylinder with pump assembly.

      Specified tightening torque 

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

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow the brake lines 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 lines 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]

      • 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)

      GTY911595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
  15. CONNECT RESERVOIR HOSE 
    1. Connect the 2 reservoir hoses to the brake master cylinder with pump assembly and slide the 2 clips to secure them.
      GTY903944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90°
      *c 30°
      Up
      NOTE:
      • Make sure that the paint mark is facing up.
      • Install the clip within the range shown in the illustration.
  16. CONNECT ENGINE ROOM MAIN WIRE 
    1. Install the engine room main wire to the vehicle body with the bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    2. Engage the clamp to the brake master cylinder with pump assembly.
      GTY920382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the connector
      Lock the lock lever
    3. Connect the connector to the brake master cylinder with pump assembly and lock the lock lever.
      NOTE:
      • 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.
    4. Connect the connector to the brake master cylinder with pump assembly.
      GTY917950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not allow water, oil or dirt to enter the connector.

  17. FILL RESERVOIR WITH BRAKE FLUID 
  18. INSTALL VEHICLE APPROACHING SPEAKER CONTROLLER 

    Refer to PROCEDURE - Step 1 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 1 [10/2022 - ]

  19. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to PROCEDURE - Step 1 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 1 [10/2022 - 11/2023]

  20. INSTALL NO. 1 SWITCH HOLE BASE 

    Refer to PROCEDURE - Step 26 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 25 [10/2022 - ]

  21. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 27 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 26 [10/2022 - ]

  22. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 28 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 27 [10/2022 - ]

  23. INSTALL ECM 

    Refer to INSTALLATION [12/2019 - 11/2023]

  24. BLEED BRAKE SYSTEM 

    See step  3

  25. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [12/2019 - 10/2022] , or refer to ADJUSTMENT [10/2022 - ] 

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

    Refer to PROCEDURE - Step 29 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 28 [10/2022 - ]

  27. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 51 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 49 [10/2022 - ]

  28. INSTALL FRONT DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 52 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 50 [10/2022 - ]

  29. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  30. INSTALL FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 16

  31. INSTALL FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  32. INSTALL FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 18

  33. INSTALL FRONT FENDER SPLASH SHIELD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  34. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 20

  35. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  36. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [12/2019 - ]

  37. PERFORM INITIALIZATION AND CALIBRATION 

    for Electronically Controlled Brake System: Refer to UTILITY [12/2019 - 11/2023]

  38. CHECK AND CLEAR DTC 

    Refer to DTC CHECK / CLEAR [12/2019 - ]

  39. INSPECT SRS WARNING LIGHT 

    Refer to OPERATION CHECK [12/2019 - 10/2022] , or refer to OPERATION CHECK [10/2022 - 11/2023]

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