Last Modified: 05-08-2025 6.11:8.1.0 Doc ID: RM100000001HIKH
Model Year Start: 2019 Model: RAV4 Prod Date Range: [02/2019 - 10/2019]
Title: BRAKE SYSTEM (OTHER): BRAKE BOOSTER (w/o Vacuum Brake Booster): REMOVAL; 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during brake booster with master cylinder assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced (for HV Model)

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link
*: When performing learning using the Techstream.

Click here 2019 - 2022 MY RAV4 HV [02/2019 - 10/2022]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system (for HV model)*

Pre-collision system

Lighting system (EXT)(w/ AFS)

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system (for HV model)

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Reset back door close position

Power back door system (for HV model)

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2025 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

Replacement of brake booster with master cylinder assembly
  • Perform initialization and calibration of the linear solenoid valve
  • Perform yaw rate and acceleration sensor zero point calibration
  • DTCs are stored
  • ABS warning light illuminates
  • Brake warning light / yellow (minor malfunction) illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): UTILITY

NOTICE:

  • After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • While the auxiliary battery is connected, even if the power 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.

Waiting Time before Disconnecting Cable from Negative (-) Auxiliary Battery Terminal

System Name

See Procedure

Vehicle enrolled in Toyota Entune system or safety connect system

6 minutes

Vehicle not enrolled in Toyota Entune system and safety connect system

1 minute

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read precaution thoroughly before servicing.

  • w/ Occupant Classification System:

    Click here 2019 - 2020 MY RAV4 RAV4 HV [02/2019 - 08/2020]; SUPPLEMENTAL RESTRAINT SYSTEMS: AIRBAG SYSTEM (w/ Occupant Classification System): PRECAUTION

  • w/o Occupant Classification System:

    Click here 2019 - 2020 MY RAV4 RAV4 HV [11/2018 - 08/2020]; SUPPLEMENTAL RESTRAINT SYSTEMS: AIRBAG SYSTEM (w/o Occupant Classification System): PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here 2019 - 2025 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. DISABLE BRAKE CONTROL

Click here 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; BRAKE (REAR): REAR BRAKE: REMOVAL+

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here 2019 - 2025 MY RAV4 RAV4 HV [11/2018 -        ]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL

4. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for A25A-FXS): REMOVAL+

5. DRAIN BRAKE FLUID

NOTICE:

If brake fluid leaks onto any painted surface, immediately wash it off.

6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

Click here 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; SUPPLEMENTAL RESTRAINT SYSTEMS: KNEE AIRBAG ASSEMBLY: REMOVAL

7. REMOVE NO. 1 AIR DUCT (for TMC Made)

Click here 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+

8. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMC Made)

Click here 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+

9. REMOVE STOP LIGHT SWITCH ASSEMBLY

Click here 2019 - 2025 MY RAV4 RAV4 HV [11/2018 -        ]; LIGHTING (EXT): STOP LIGHT SWITCH: REMOVAL

10. REMOVE BRAKE PEDAL RETURN SPRING

Click here 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/o Vacuum Brake Booster): REMOVAL+

11. SEPARATE WIRE HARNESS

(a) Disconnect the connector from the brake pedal stroke sensor assembly.

(b) Disengage the 2 clamps to separate the wire harness from the brake pedal support assembly.

12. REMOVE PUSH ROD PIN

Click here 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/o Vacuum Brake Booster): REMOVAL+

13. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

(a) Remove the 2 nuts and separate the brake master cylinder reservoir assembly.

14. DISCONNECT NO. 2 RESERVOIR HOSE

(a) Slide the clip and disconnect the No. 2 reservoir hose from the brake booster with master cylinder assembly.

15. DISCONNECT NO. 1 RESERVOIR HOSE

(a) Slide the clip and disconnect the No. 1 reservoir hose from the brake booster with master cylinder assembly.

16. DISCONNECT NO. 1 BRAKE ACTUATOR HOSE

(a) Slide the clip and disconnect the brake actuator hose from the brake master cylinder reservoir assembly.

17. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH RESERVOIR HOSE

(a) Remove the brake master cylinder reservoir with reservoir hose

18. REMOVE RESERVOIR BRACKET

(a) Remove the bolt, 2 nuts and reservoir bracket.

19. SEPARATE NO. 1 BRAKE ACTUATOR TUBE

(a) Remove the 2 nuts and separate the No. 1 brake actuator tube from the vehicle body.

20. DISCONNECT NO. 4 FRONT BRAKE TUBE

(a) Using a union nut wrench, disconnect the No. 4 front brake tube.

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

21. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) Disengage the clamp to separate the wire harness.

Release the lock lever

Disconnect the connector

(b) Release the lock lever and disconnect the connector from the brake booster with master cylinder assembly.

NOTICE:

Be careful not to allow brake fluid to enter the removed connector.

(c) Using a union nut wrench, disconnect the 5 brake lines from the brake booster with master cylinder assembly.

*a

To Front Wheel Cylinder LH

*b

To Rear Wheel Cylinder RH

*c

To Brake Booster Pump Assembly

*d

To Rear Wheel Cylinder LH

*e

To Front Wheel Cylinder RH

(d) Use tags or make a memo to identify the places to reconnect.

(e) Disengage the 8 clamps to remove the 2 brake tube clamps from the brake lines.

(f) Disengage the 4 clamps to remove the brake tube clamp from the brake lines.

(g) Disengage the clamp and remove the brake tube clamp from the vehicle body.

(h) Disengage the clamp to remove the No. 4 front brake tube with brake tube clamp from the brake line.

(i) Disengage the clamp to remove the brake tube clamp from the No. 4 front brake tube.

(j) Remove the 4 nuts and brake booster with master cylinder assembly.

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not carry the brake booster with master cylinder assembly by the portion shown in the illustration.

*1

Connector Portion

*2

Union

*3

Push Rod Clevis

*4

Boot

*5

Front No. 2 Brake Tube

22. REMOVE BRAKE BOOSTER GASKET