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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) (Service Information) (Hybrid) >> Brake Master Cylinder >> Installation [02/2014 - 11/2016] >> Procedure

Installation [02/2014 - 11/2016]: Procedure

  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY 
    1. Install the brake master cylinder sub-assembly, brake stroke simulator cylinder with bracket and 2 new brake master cylinder gaskets to the brake master cylinder bracket as shown in the illustration.
      GTY453734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Master Cylinder Sub-assembly *2 Brake Stroke Simulator Cylinder with Bracket
      *3 Brake Master Cylinder Gasket *4 Brake Master Cylinder Bracket
    2. Install the 2 nuts to secure them.

      Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf) 

  2. INSTALL BRAKE STROKE SIMULATOR TUBE 
    1. Using a union nut wrench, install the brake stroke simulator tube to the brake master cylinder sub-assembly and brake stroke simulator cylinder sub-assembly.
      GTY435066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Do not kink or damage the brake stroke simulator tube.
      • Do not allow any foreign matter such as dirt or dust to enter the brake stroke simulator tube from the connecting parts.
      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Refer to PRECAUTION [02/2014 - 11/2016]

  3. INSTALL BRAKE MASTER CYLINDER GASKET 
    1. Install a new brake master cylinder gasket to the brake master with stroke simulator cylinder assembly.
  4. INSTALL BRAKE MASTER WITH STROKE SIMULATOR CYLINDER ASSEMBLY 
    1. Install the brake master with stroke simulator cylinder assembly with the 4 nuts.

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

      NOTE:

      Do not kink or damage the brake lines.

    2. Connect the connector to the brake stroke simulator cylinder sub-assembly.
  5. INSTALL PUSH ROD PIN 

    See step  3

  6. INSTALL BRAKE PEDAL RETURN SPRING 

    See step  4

  7. CONNECT FRONT NO. 7 BRAKE TUBE 
    1. Using a union nut wrench, connect the front No. 7 brake tube to the brake stroke simulator cylinder sub-assembly.
      GTY435096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Do not kink or damage the front No. 7 brake tube.
      • Do not allow the front No. 7 brake tube 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 front No. 7 brake tube from the connecting parts.
      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Refer to PRECAUTION [02/2014 - 11/2016]

  8. CONNECT FRONT NO. 6 BRAKE TUBE 
    1. Using a union nut wrench, connect the front No. 6 brake tube to the brake master cylinder sub-assembly.
      GTY435097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Do not kink or damage the front No. 6 brake tube.
      • Do not allow the front No. 6 brake tube 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 front No. 6 brake tube from the connecting parts.
      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Refer to PRECAUTION [02/2014 - 11/2016]

  9. CONNECT NO. 2 RESERVOIR HOSE 
    1. Connect the No. 2 reservoir hose to the brake master cylinder sub-assembly, and slide the clip to secure it.
      GTY435095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT NO. 1 RESERVOIR HOSE 
    1. Connect the No. 1 reservoir hose to the brake master cylinder sub-assembly, and slide the clip to secure it.
      GTY452859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  12. INSTALL INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 4

  13. INSTALL INLET NO. 2 AIR CLEANER 

    Refer to PROCEDURE - Step 5

  14. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  15. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  16. INSTALL RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  17. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 6

  18. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10 , or refer to PROCEDURE - Step 10

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to PROCEDURE - Step 3

  20. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 68 , or refer to PROCEDURE - Step 67

  21. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 4

  22. BLEED BRAKE MASTER CYLINDER 

    Refer to BLEEDING [02/2014 - ] 

  23. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [02/2014 - ] 

  24. CHECK BRAKE MASTER CYLINDER WITH TECHSTREAM 

    Refer to ON-VEHICLE INSPECTION [02/2014 - ] 

  25. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [02/2014 - 11/2016]

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