BRAKE SYSTEM (OTHER): BRAKE BOOSTER (w/o Vacuum Brake Booster): REMOVAL; 2020 MY RAV4 RAV4 HV [10/2019

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001LTXY
Model Year Start: 2020	Model: RAV4	Prod Date Range: [10/2019 - 08/2020]
Title: BRAKE SYSTEM (OTHER): BRAKE BOOSTER (w/o Vacuum Brake Booster): REMOVAL; 2020 MY RAV4 RAV4 HV [10/2019 - 08/2020]

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
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for HV model)*
		Pre-collision system
		Lighting system (EXT)(w/ AFS)
	Memorize steering angle neutral point	Parking assist monitor system
	Memorize steering angle neutral point	Panoramic view monitor system (for HV model)
	Reset back door close position	Power back door system (for HV model)
	Back door lock initialization	Power door lock control system
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

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 Audio Multimedia system or safety connect system	6 minutes
Vehicle not enrolled in Toyota Audio Multimedia 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
w/o Occupant Classification System:
Click here

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

2. DISABLE BRAKE CONTROL

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

4. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY

Click here

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

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

Click here

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

Click here

9. REMOVE STOP LIGHT SWITCH ASSEMBLY

Click here

10. REMOVE BRAKE PEDAL RETURN SPRING

Click here

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

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.

*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