Toyota Highlander manuals

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

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

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

REMOVE BRAKE BOOSTER ASSY


(a) Slide the clip and disconnect the vacuum hose from the check valve assy.

REMOVE BRAKE BOOSTER 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

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

 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.

 INSTALL BRAKE BOOSTER ASSY


(b) Connect the vacuum hose to the brake booster assy and slide the clip.

18. INSTALL BRAKE TUBE

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

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 ...

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Valve clearance (3MZ-FE)
ADJUSTMENT 1. DRAIN ENGINE COOLANT (See page 16-26 ) 2. REMOVE FR WIPER ARM LH (See page 66-7 ) 3. REMOVE FR WIPER ARM RH (See page 66-7 ) 4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) 5. REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) 6. REMOVE COWL PANEL SUB-ASSY 7. REMO ...

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