BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/ Vacuum Brake Booster): ADJUSTMENT; 2019 - 2021 MY RAV4 RAV4 HV [11/2018

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001GIKS
Model Year Start: 2019	Model: RAV4	Prod Date Range: [11/2018 - 12/2021]
Title: BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/ Vacuum Brake Booster): ADJUSTMENT; 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]

ADJUSTMENT

PROCEDURE

1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

(a) Remove the front door scuff plate LH.

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(b) Remove the cowl side trim board LH.

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HINT:

Perform checks and adjustments with the service hole carpet rolled back.

(1) Measure the shortest distance between the brake pedal pad surface and front floor footrest as shown in the illustration.

*1	Brake Pedal Pad	-	-
*a	Brake Pedal Height	*b	Measuring Plane of Floor Panel
	Service Hole	-	-

Brake Pedal Height from Floor Panel:

155.6 to 171.6 mm (6.13 to 6.75 in.)

If the brake pedal height is not as specified, inspect and adjust the push rod length according to the procedure below.

(d) Adjust the push rod length.

(1) Remove the stop light switch assembly.

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*1	Lock Nut
*2	Stop Light Switch Assembly
*3	Floor Panel
*a	Brake Pedal Height

(2) Loosen the lock nut.

(3) Adjust the brake pedal height by turning the push rod.

Brake Pedal Height from Front Floor Panel:

155.6 to 171.6 mm (6.13 to 6.75 in.)

(4) Tighten the lock nut.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(5) Install the stop light switch assembly.

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(e) Install the cowl side trim board LH.

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(f) Install the front door scuff plate LH.

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2. INSPECT BRAKE PEDAL FREE PLAY

(a) Stop the engine and firmly depress the brake pedal several times until no vacuum is left in the brake booster assembly.

(b) Depress the brake pedal until a slight resistance is felt. Measure the distance as shown in the illustration.

Brake Pedal Free Play:

1.0 to 6.0 mm (0.0394 to 0.236 in.)

If the brake pedal free play is not as specified, check the stop light switch clearance.

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If the brake pedal free play is as specified, proceed to the Inspect Brake Pedal Reserve Distance procedure.

*a	Brake Pedal Free Play

3. INSPECT BRAKE PEDAL RESERVE DISTANCE

(a) With the engine running, depress the brake pedal and measure the brake pedal reserve distance as shown in the illustration.

HINT:

Perform checks with the service hole carpet rolled back.

*1	Brake Pedal Pad	-	-
*a	Brake Pedal Reserve Distance	*b	Measuring Plane of Floor Panel
	Service Hole	-	-

Brake Pedal Reserve Distance from Floor Panel at 300 N (30.5 kgf, 67.4 lbf):

129 mm (5.079 in.) or more

If the distance is not as specified, troubleshoot the brake system.

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