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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 >> Removal [02/2014 - 11/2016] >> Procedure

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

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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

  2. DISCONNECT BRAKE BOOSTER PUMP CONNECTOR 

    Refer to PROCEDURE - Step 2

  3. PERFORM ACCUMULATOR PRESSURE ZERO DOWN 

    Refer to PROCEDURE - Step 3

  4. DRAIN BRAKE FLUID 
    NOTE:
    • If brake fluid leaks onto any painted surface, immediately wash it off.
    • If air has leaked into the No. 2 brake actuator hose (the hose between the brake booster pump assembly and brake master cylinder reservoir sub-assembly), use the same bleeding method as for the brake actuator assembly.
  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

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

  6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3 , or refer to PROCEDURE - Step 3

  8. REMOVE V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 22 , or refer to PROCEDURE - Step 22

  9. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 1

  10. REMOVE RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 2

  11. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3

  12. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  13. REMOVE INLET NO. 2 AIR CLEANER 

    Refer to PROCEDURE - Step 9

  14. REMOVE INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 10

  15. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 11

  16. DISCONNECT NO. 1 RESERVOIR HOSE 
    1. Slide the clip and disconnect the No. 1 reservoir hose from the brake master cylinder sub-assembly.
      GTY452859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT NO. 2 RESERVOIR HOSE 
    1. Slide the clip and disconnect the No. 2 reservoir hose from the brake master cylinder sub-assembly.
      GTY435095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT FRONT NO. 6 BRAKE TUBE 
    1. Using a union nut wrench, disconnect the front No. 6 brake tube from the brake master cylinder sub-assembly.
      GTY435097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage or deform the front No. 6 brake tube during the removal procedure.
      • Do not allow any foreign matter such as dirt or dust to enter the front No. 6 brake tube from the connecting parts.
  19. DISCONNECT FRONT NO. 7 BRAKE TUBE 
    1. Using a union nut wrench, disconnect the front No. 7 brake tube from the brake stroke simulator cylinder sub-assembly.
      GTY435096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage or deform the front No. 7 brake tube during the removal procedure.
      • Do not allow any foreign matter such as dirt or dust to enter the front No. 7 brake tube from the connecting parts.
  20. REMOVE BRAKE PEDAL RETURN SPRING 

    See step  5

  21. REMOVE PUSH ROD PIN 

    See step  6

  22. REMOVE BRAKE MASTER WITH STROKE SIMULATOR CYLINDER ASSEMBLY 
    1. Disconnect the connector from the brake stroke simulator cylinder sub-assembly.
      GTY435068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and brake master with stroke simulator cylinder assembly.
      GTY434980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not kink or damage the brake lines.

  23. REMOVE BRAKE MASTER CYLINDER GASKET 
  24. REMOVE BRAKE STROKE SIMULATOR TUBE 
    1. Using a union nut wrench, remove the brake stroke simulator tube from the brake master cylinder sub-assembly and brake stroke simulator cylinder sub-assembly.
      GTY435066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not allow any foreign matter such as dirt or dust to enter the brake stroke simulator tube from the connecting parts.
      • Do not kink or damage the brake stroke simulator tube.
  25. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY 
    1. Remove the 2 nuts, brake master cylinder sub-assembly, brake stroke simulator cylinder with bracket and 2 brake master cylinder gaskets from the brake master cylinder bracket.
      GTY435067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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