Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FHJY
Model Year Start: 2019 Model: RAV4 Prod Date Range: [11/2018 - 12/2021]
Title: BRAKE (FRONT): FRONT BRAKE: INSTALLATION; 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

  • Immediately after installing the brake pads, the braking performance may be reduced. Always perform a road test in a safe place while paying attention to the surroundings.
  • After replacing the front disc brake pads, the brake pedal may feel soft due to clearance between the front disc brake pads and front disc. Depress the brake pedal several times until the brake pedal feels firm.
  • After replacing the front disc brake pads, always perform a road test to check the braking performance and check for vibrations.
  • When the brake pedal is first depressed after replacing the brake pads or pushing back the disc brake piston, DTC C1214 may be stored. As there is no malfunction, clear the DTC. (for HV Model)
  • While the auxiliary battery is connected, even if the ignition switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected. (for HV Model)

HINT:

  • Use the same procedure for the RH and LH sides.
  • The following procedure is for the LH side.

PROCEDURE

1. INSTALL FRONT DISC

(a) Align the matchmarks of the front disc and front axle hub sub-assembly, and install the front disc.

NOTICE:

When replacing the front disc with a new one, select the installation position where the front disc has minimal runout.

*a

Matchmark

2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

(a) Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.

Torque:

for Steel Steering Knuckle :

107 N·m {1091 kgf·cm, 79 ft·lbf}

for Aluminum Steering Knuckle :

150 N·m {1530 kgf·cm, 111 ft·lbf}

3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT

(a) Apply a thin layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.

HINT:

Apply more than 0.3 g (0.01 oz) of lithium soap base glycol grease to each front disc brake bushing dust boot.

Lithium Soap Base Glycol Grease

(b) Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.

4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a thin layer of lithium soap base glycol grease to the contact surface of the front disc brake cylinder slide pin (lower side).

Lithium Soap Base Glycol Grease

(b) Install a new front disc brake cylinder slide bushing to the front disc brake cylinder slide pin (lower side).

(c) Apply a thin layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the 2 front disc brake cylinder slide pins.

Lithium Soap Base Glycol Grease

(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting.

(e) Push each front disc brake cylinder slide pin into the front disc brake bushing dust boot to engage the pin to the boot.

5. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

(a) Install the 4 front disc brake pad support plates to the front disc brake cylinder mounting.

NOTICE:

Be sure to install each front disc brake pad support plate in the correct position and direction.

6. INSTALL FRONT DISC BRAKE ANTI-SQUEAL SHIM KIT

Click here 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; MAINTENANCE: FRONT DISC BRAKE PAD: INSTALLATION+

7. INSTALL FRONT DISC BRAKE PAD

(a) Install the 2 front disc brake pads to the front disc brake cylinder mounting.

NOTICE:

  • Keep the friction surfaces of the front disc brake pads and front disc free from oil and grease.
  • Install the front disc brake pad so that the pad wear indicator plate is mounted on the upper side of the vehicle.

8. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY

(a) Hold each front disc brake cylinder slide pin and install the front disc brake cylinder assembly to the front disc brake cylinder mounting with the 2 bolts.

Torque:

34.3 N·m {350 kgf·cm, 25 ft·lbf}

9. CONNECT FRONT FLEXIBLE HOSE

(a) Connect the front flexible hose to the front disc brake cylinder assembly with a new union bolt and a new gasket.

Torque:

29.4 N·m {300 kgf·cm, 22 ft·lbf}

NOTICE:

Install the front flexible hose lock securely into the lock hole in the front disc brake cylinder assembly.

10. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (w/o Vacuum Brake Booster)

(a) Connect the reservoir level switch connector.

(b) Connect the cable to the negative (-) auxiliary battery terminal.

Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: INSTALLATION+ 2021 - 2024 MY RAV4 HV [08/2020 -        ]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: INSTALLATION+

(c) Perform the following procedure if air bleeding is not necessary:

(1) Turn the ignition switch on (READY).

(2) Depress the brake pedal and release it.

(3) Clear the DTCs.

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): DTC CHECK / CLEAR 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): DTC CHECK / CLEAR

11. BLEED BRAKE LINE

  • w/ Vacuum Brake Booster: Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; BRAKE SYSTEM (OTHER): BRAKE FLUID(w/ Vacuum Brake Booster): BLEEDING
  • w/o Vacuum Brake Booster: Click here 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; BRAKE SYSTEM (OTHER): BRAKE FLUID (w/o Vacuum Brake Booster): BLEEDING

12. INSTALL FRONT WHEEL

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; MAINTENANCE: TIRE AND WHEEL: INSTALLATION