Toyota Highlander Service Manual: Replacement
1. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (SEE PAGE 32-14 )
2. REMOVE AIR CLEANER ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 )
3. REMOVE AIR CLEANER CAP SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )
4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )
5. REMOVE AIR CLEANER CASE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )
6. DRAIN BRAKE FLUID
NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.
7. REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE PAGE 32-14 )
SST 09023-00101
8. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 )
9. REMOVE BRAKE PEDAL RETURN SPRING
(a) Remove the brake pedal return spring.
10. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Remove the clip and the push rod pin.
(b) Loosen the push rod lock nut and remove the push rod clevis.
11. SEPARATE BRAKE TUBE
(a) Release the 2 claw fittings of the clamp and separate the 2 brake tubes from the body.
SST 09023-00101
NOTICE: Be careful not to damage the brake tubes.
12. REMOVE BRAKE BOOSTER ASSY
(a) Slide the clip and disconnect the vacuum hose from the check valve assy.
(b) Remove the 4 nuts and pull out the brake booster assy.
NOTICE: Be careful not to damage the brake tubes and the wire harness.
13. REMOVE BRAKE BOOSTER GASKET
(a) Remove the brake booster gasket from the brake booster assy.
14. REMOVE BRAKE VACUUM CHECK VALVE ASSY
(a) Remove the check valve assy and the grommet from the brake booster assy.
15. INSTALL BRAKE VACUUM CHECK VALVE ASSY
(a) Install the grommet and the check valve assy to the brake booster assy.
16. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assy.
17. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster assy with the 4 nuts.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
NOTICE: Be careful not to damage the brake tubes and the wire harness.
(b) Connect the vacuum hose to the brake booster assy and slide the clip.
18. INSTALL BRAKE TUBE
(a) Install the 2 clamps of the brake tube to the body.
SST 09023-00101
NOTICE: Be careful not to damage the brake tubes.
19. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and the push rod lock nut.
HINT: After adjusting the brake pedal height, torque the lock nut.
(b) Apply lithium soap base glycol grease to the clevis pin.
(c) Install the push rod pin and the clip.
20. INSTALL BRAKE PEDAL RETURN SPRING
(a) Install the brake pedal return spring.
21. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-14 )
SST 09737-00020
22. INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE PAGE 32-14 )
SST 09023-00101
23. FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32-4 )
24. BLEED MASTER CYLINDER (SEE PAGE 32-4 )
SST 09023-00101
25. BLEED BRAKE LINE (SEE PAGE 32-4 )
26. BLEED BRAKE ACTUATOR ASSY (SEE PAGE 32-4 )
27. CHECK BRAKE FLUID LEAKAGE
28. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 )
29. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8 )
30. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER
31. INSTALL AIR CLEANER ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 )
32. INSTALL AIR CLEANER CASE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )
33. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )
34. INSTALL AIR CLEANER CAP SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )
35. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (SEE PAGE 32-14 )
On-vehicle inspection
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
HINT:
If the pedal can be depress ...
Front brake
COMPONENTS
OVERHAUL
HINT:
Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Was ...
More about Toyota Highlander:
Fan and generator v belt (2AZ-FE)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER SPLASH SHIELD FRONT RH
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE ENGINE MOUNTING STAY NO.2 RH
5. REMOVE ENGINE COVER SUB-ASSY NO.1
6. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 )
7. REMOVE ENGINE MOUNTING BRACKET ...
