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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Brakes >> Anti-Lock Brakes >> Brake Control System - Service Information >> BRAKE ACTUATOR (for HV Model) >> Installation [12/2019 - 11/2023] >> Procedure

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

  1. INSTALL BRAKE ACTUATOR BRACKET CUSHION 

    HINT: 

    Perform this procedure only when replacement of the brake actuator bracket cushions is necessary.

    1. Install the 3 brake actuator bracket cushions to the brake actuator bracket assembly.
  2. INSTALL NO. 2 BRAKE ACTUATOR CASE COLLAR 

    HINT: 

    Perform this procedure only when replacement of the No. 2 brake actuator case collars is necessary.

    1. Install the 3 No. 2 brake actuator case collars to the brake actuator bracket cushion.
      NOTE:

      Make sure that the No. 2 brake actuator case collar is in full contact with the brake actuator bracket cushion.

    2. Install the 3 nuts.

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

  3. INSTALL BRAKE ACTUATOR ASSEMBLY 
    1. Temporarily install the brake actuator assembly to the brake actuator bracket assembly with the bolt (A).
      Fig 1: Brake Actuator Assembly Bolts Tightening Sequence
      GTY856776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts in the order shown in the illustration.

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

      NOTE:
      • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.
      • Do not hold the brake actuator assembly by the connector.
      • Do not drop the brake actuator assembly when carrying it.
  4. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Temporarily install the brake actuator with bracket with the 2 bolts and nut.
      GTY912116Courtesy 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.
      • Be careful not to allow any brake fluid to enter the connector.
      • Do not hold the brake actuator with bracket by the connector.
      • Do not drop the brake actuator with bracket when carrying it.

      HINT: 

      Install the brake actuator with bracket while avoiding the brake lines.

    2. Tighten the 2 bolts and nut in the order shown in the illustration.

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

    3. Engage the clamp to install a new brake tube clamp.
      GTY943771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Return the front brake tube to its original position.
      NOTE:

      Do not apply excessive force to the front brake tube.

    5. Temporarily install the front brake tube to the front flexible hose.
      NOTE:
      • Do not kink or damage the front brake tube.
      • Do not allow any foreign matter such as dirt or dust to enter the front brake tube from the connecting parts.
      GTY912130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the clamp to connect the front brake tube.
      GTY917942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not kink or damage the front brake tube.

    7. Temporarily tighten the 2 brake lines to the correct position on the brake actuator assembly as shown in the illustration.
      GTY911666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly
      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.
    8. Using a union nut wrench, fully tighten the 2 brake lines.

      Specified tightening torque 

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

      GTY903998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:

      Do not kink or damage the brake lines.

      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)

    9. GTY920400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Front Wheel Cylinder Assembly RH
      *b To Front Wheel Cylinder Assembly LH
      *c To Rear Wheel Cylinder Assembly RH
      *d To Rear Wheel Cylinder Assembly LH

      Temporarily tighten the 4 brake lines to the correct position on the brake actuator assembly as shown in the illustration.

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.
    10. Using a union nut wrench, fully tighten the 4 brake lines.

      Specified tightening torque 

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

      GTY915050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:

      Do not kink or damage the brake lines.

      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)

    11. Using a union nut wrench, fully tighten the front brake tube while holding the front flexible hose with a wrench.

      Specified tightening torque 

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

      GTY852623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:

      Do not kink or damage the front brake tube.

      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)

    12. Install the brake lines with the bolt.
      GTY917400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.0 N.m (71 kgf/cm, 62 in.lbf) 

    13. Connect the connector to the brake actuator assembly and lock the lock lever.
      GTY848995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the connector
      Lock the lock lever
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the actuator connector can be connected smoothly.
      • Do not allow water, oil or dirt to enter the connector.
  5. CONNECT BRAKE BOOSTER WITH ACCUMULATOR PUMP CONNECTOR 

    HINT: 

    Perform this operation only when the accumulator pressure zero down could not be performed using the GTS.

    1. Connect the brake booster with accumulator pump connector.
      GTY917950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  6. FILL RESERVOIR WITH BRAKE FLUID 
  7. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

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

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [12/2019 - 09/2020] , or refer to INITIALIZATION [09/2020 - 10/2021] , or refer to INITIALIZATION [10/2021 - 10/2022] , or refer to INITIALIZATION [10/2022 - 11/2023]

  8. BLEED BRAKE SYSTEM 

    Refer to PROCEDURE - Step 3

  9. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

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

    Refer to PROCEDURE - Step 16

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

    HINT: 

    Perform the same procedure as for the LH side.

  12. INSTALL FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 18

  13. INSTALL FRONT FENDER SPLASH SHIELD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  14. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 20

  15. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  16. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [12/2019 - ]

  17. PERFORM INITIALIZATION AND CALIBRATION 

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

    for Electric Parking Brake System: Refer to PRECAUTION [12/2019 - 10/2022] , or refer to PRECAUTION [10/2022 - 11/2023]

  18. CHECK AND CLEAR DTC 

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

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