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Home >> Toyota >> 2017 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) (Service Information) (Except Hybrid) >> Brake Booster >> Removal [12/2013 - 11/2016] >> Procedure

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

  1. PRECAUTION 
    NOTE:

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

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

  2. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY 

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

  3. SEPARATE BRAKE BOOSTER VACUUM EJECTOR (for 1AR-FE) 
    1. Remove the 2 nuts and separate the brake booster vacuum ejector from the outer cowl top panel sub-assembly.
      GTY429621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2013 - ]

  5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 , or refer to PROCEDURE - Step 4

  6. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disconnect the reservoir level switch connector and remove the bolt from the brake master cylinder reservoir assembly.
      GTY442348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket
    2. Move the brake master cylinder reservoir assembly as shown in the illustration to disengage the 2 claws, and remove it.
  7. REMOVE RESERVOIR BRACKET 
    1. Remove the 2 bolts and reservoir bracket.
      GTY429787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE ECM 

    for 1AR-FE: Refer to PROCEDURE - Step 4

    for 2GR-FE: Refer to PROCEDURE - Step 4

  9. SEPARATE ENGINE ROOM MAIN WIRE 
    1. Disengage the 5 clamps to separate the engine room main wire.
      GTY429784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/ Security Horn Assembly:
      GTY434378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Pin
      1. Disconnect the connector from the security horn assembly.
    3. Remove the bolt.
    4. Disengage the 2 clamps and pin to separate the wire harness protector.
    5. Remove the 2 bolts.
      GTY429790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disengage the 2 pins to separate the engine room relay block assembly.
  10. SEPARATE ENGINE WIRE 
    1. Disengage the 3 clamps to separate the engine wire.
      GTY429788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Slide the clip and disconnect the fuel vapor feed hose assembly.
      GTY429785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR (for 1AR-FE) 
    1. Slide the 2 clips and disconnect the 2 union to check valve hoses from the brake booster assembly.
      GTY429622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and separate the No. 1 vacuum hose connector.
      GTY429623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT UNION TO CHECK VALVE HOSE (for 2GR-FE) 
    1. Slide the clip and disconnect the union to check valve hose from the brake booster assembly.
      GTY429786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. SEPARATE SUCTION HOSE SUB-ASSEMBLY 
    1. Disengage the claw to release the piping clamp.
      GTY451701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the suction hose sub-assembly from the piping clamp.
      NOTE:
      • Do not deform the refrigerant lines.
      • Do not damage the clamp.
  15. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the nut and separate the air conditioner tube and accessory assembly.
      GTY429630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not deform the refrigerant lines.
      • Do not damage the clamp.
  16. SEPARATE BRAKE LINE 
    1. Remove the bolt and separate the front No. 1 brake tube way.
      GTY436527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front No. 1 Brake Tube Way
    2. Disengage the brake tube clamp to separate the 3 brake lines.
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not damage the clamp.
  17. REMOVE BRAKE PEDAL RETURN SPRING 

    See step  4

  18. LOOSEN LOCK NUT 
    1. Loosen the lock nut of the brake master cylinder push rod clevis.
      GTY450232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Lock Nut
      *2 Brake Master Cylinder Push Rod Clevis
  19. REMOVE PUSH ROD PIN 

    See step  5

  20. REMOVE BRAKE BOOSTER ASSEMBLY 
    1. Remove the 4 nuts and push the brake booster assembly toward the engine compartment.
      GTY429721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.
    3. Remove the brake booster assembly from the vehicle body.
      NOTE:

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

  21. REMOVE BRAKE BOOSTER GASKET 
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