Toyota Highlander Hybrid 6 2005-06

Actuator

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the brake fluid
    WARNING
    Do not let brake fluid sit on painted surfaces, as it will eat through the paint. Wash it off immediately.

  4.  
  5. Remove air cleaner assembly with hose
  6.  
  7. Remove the brake actuator with the bracket, as follows:
  8.  
  9. Using a suitable brake line tool, disconnect the 6 brake lines from the actuator. Tag or note the installed position of the lines before disconnecting them.

    Click image to see an enlarged view

    Fig. Tag or note the installed positions of the brake lines before disconnecting them from the actuator

    1. Pull the lock lever upward.
    2.  
    3. Disconnect the actuator connector.

      Click image to see an enlarged view

      Fig. Pull the lock lever up (c), then detach the actuator electrical connector (d)

    4.  
    5. Remove the 2 bolts, the nut and the actuator with bracket.
      WARNING
      Be careful not to damage the brake tubes and wire harness.



      Click image to see an enlarged view

      Fig. Unfasten the 2 bolts and nut, then remove the actuator with the bracket

    6.  

  10.  
  11. Remove the brake actuator assembly, as follows:
    1. Remove the 2 nuts and the brake actuator assembly from the brake actuator bracket.
    2.  

  12.  

To install:

  1. Install the brake actuator assembly with the 2 nuts. Tighten to 48 inch lbs. (5.4 Nm).
  2.  

  1. Install brake actuator with bracket, as follows:
    1. Install the actuator with bracket and the 2 bolts and the nut. Tighten to 14 ft. lbs. (19 Nm).
      WARNING
      Be careful not to damage the brake tubes and wire harness.

    2.  
    3. Connect the actuator connector.
    4.  
    5. Using a suitable brake line tool, connect each brake tube to correct positions of the actuator with bracket, as tagged during removal. Tighten to 11 ft. lbs. (15 Nm).
    6.  

  2.  
  3. Fill reservoir with brake fluid.
  4.  
  5. Bleed the master cylinder, brake lines and actuator, as outlined at the beginning of this section.
  6.  
  7. Check the fluid level and inspect for brake fluid leakage.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Check brake actuator using a hand-held tester, as follows:
    1. Connect a hand-held tester to the DLC3.

      Click image to see an enlarged view

      Fig. Connect a hand-held tester to the DLC3

    2.  
    3. Start the engine and run at idle.
    4.  
    5. Select the ACTIVE TEST mode on the hand-held tester.
      NOTE
      Please refer to the hand-held tester operator-s manual for more information.

    6.  
    7. INSPECT ACTUATOR MOTOR OPERATION
    8.  
    9. With the motor relay on, check the actuator motor operation noise.
    10.  
    11. Turn the motor relay off.
    12.  
    13. Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed.
    14.  
    15. With the motor relay on, check that the pedal does not pulsate.
      NOTE
      Do not keep a motor relay on for more than 5 seconds continuously. When operating it continuously, set an interval of more than 20 seconds.

    16.  
    17. Turn the motor relay off and release the brake pedal.
    18.  
    19. INSPECT RIGHT FRONT WHEEL OPERATION
      NOTE
      Never turn on the solenoids in a manner different to those described below.

    20.  
    21. With the brake pedal depressed, perform the following operations.
    22.  
    23. Turn the SFRH and SFRR solenoids on simultaneously, and check that the pedal cannot be depressed.
      NOTE
      Do not keep a solenoid turned on for more than 10 seconds continuously. When operating it continuously, set an interval of more than 20 seconds.

    24.  
    25. Turn the SFRH and SFRR solenoids off simultaneously, and check that the pedal can be depressed.
    26.  
    27. Turn the motor relay on, and check that the pedal returns.
      NOTE
      Do not keep a motor relay turned on for more than 5 seconds continuously. When operating it continuously, set an interval of more than 20 seconds.

    28.  
    29. Turn the motor relay off and release the brake pedal.
    30.  
    31. INSPECT OTHER WHEEL OPERATION
    32.  
    33. Using the same procedure, check the solenoids of the other wheels.

      Left front wheel: SFLH, SFLR
       
      Right rear wheel: SRRH, SRRR
       
      Left rear wheel: SRLH, SRLR
       

    34.  

  12.  

 
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