LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2017 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) (Service Information) (Except Hybrid) >> Brake Booster >> Installation [12/2013 - 11/2016] >> Procedure

Installation [12/2013 - 11/2016]: Procedure

  1. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assembly.
  2. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Temporarily install the brake booster assembly to the vehicle body.
      NOTE:

      Do not apply excessive force to the brake lines or refrigerant lines.

    2. Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.
      NOTE:

      Fully tighten the lock nut when adjusting the brake pedal height.

    3. Install the 4 nuts to secure the brake booster assembly.

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

  3. INSTALL PUSH ROD PIN 

    See step  3

  4. INSTALL BRAKE PEDAL RETURN SPRING 

    See step  4

  5. INSTALL BRAKE LINE 
    1. Install the 3 brake lines to the brake tube clamp.
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not damage the clamp.
    2. Install the bolt to secure front No. 1 brake tube way.

      Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 

      NOTE:

      Do not kink or damage the brake lines.

  6. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Install the air conditioner tube and accessory assembly with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      NOTE:
      • Do not deform the refrigerant lines.
      • Do not damage the clamp.
  7. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Install the suction hose sub-assembly to the piping clamp.
      GTY429794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not deform the refrigerant lines.
      • Do not damage the clamp.
    2. Engage the claw to secure the suction hose sub-assembly.
  8. CONNECT NO. 1 VACUUM HOSE CONNECTOR (for 1AR-FE) 
    1. Install the No. 1 vacuum hose connector with the 2 nuts.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    2. Connect the 2 union to check valve hoses to the brake booster assembly, and slide the 2 clips to secure them.
  9. CONNECT UNION TO CHECK VALVE HOSE (for 2GR-FE) 
    1. Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.
  10. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Connect the fuel vapor feed hose assembly, and slide the clip to secure it.
  11. INSTALL ENGINE WIRE 
    1. Engage the 3 clamps to install the engine wire.
  12. INSTALL ENGINE ROOM MAIN WIRE 
    1. Engage the 2 pins to install the engine room relay block assembly.
    2. Install the 2 bolts.
    3. Engage the 2 clamps and pin to install the wire harness protector.
      GTY434378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Pin
    4. Install the bolt to secure the wire harness protector.
    5. w/ Security Horn Assembly:
      1. Connect the connector to the security horn assembly.
    6. Engage the 5 clamps to install the engine room main wire.
  13. INSTALL ECM 

    for 1AR-FE: Refer to PROCEDURE - Step 3

    for 2GR-FE: Refer to PROCEDURE - Step 3

  14. INSTALL RESERVOIR BRACKET 
    1. Install the reservoir bracket with the 2 bolts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  15. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Move the brake master cylinder reservoir assembly as shown in the illustration to engage the 2 claws.
      GTY426172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket
    2. Connect the reservoir level switch connector and install the bolt.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

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

  17. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to PROCEDURE - Step 3

  18. INSTALL BRAKE BOOSTER VACUUM EJECTOR (for 1AR-FE) 
    1. Install the brake booster vacuum ejector to the outer cowl top panel sub-assembly with the 2 nuts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  19. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY 

    Refer to INSTALLATION [12/2013 - 11/2016] 

  20. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [12/2013 - ]