| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM1000000021J1S |
| Model Year Start: 2022 | Model: RAV4 | Prod Date Range: [12/2021 - ] |
| Title: BRAKE SYSTEM (OTHER): BRAKE SYSTEM (w/o Vacuum Brake Booster): ON-VEHICLE INSPECTION; 2022 - 2024 MY RAV4 RAV4 HV [12/2021 - ] | ||
ON-VEHICLE INSPECTION
CAUTION / NOTICE / HINT
NOTICE:
DTCs may be stored during the inspection procedure. Be sure to clear the DTCs and check that no DTCs are output after the inspection is finished.
PROCEDURE
1. INSPECT PRESSURE SENSOR
(a) Check the auxiliary battery voltage.
Standard Voltage:
11 to 14 V (while the ignition switch is off)
(b) Set a pedal effort gauge and SST.
HINT:
Simultaneously measure the brake fluid pressure of all 4 wheels, or 2 wheels at a time.
|
(1) Set a pedal effort gauge and SST. SST: 09709-29018 09709-00060 |
|
(2) Move the shift lever to P and apply the parking brake.
(3) Bleed air from SST (LSPV gauge).
Click here
![2022 - 2024 MY RAV4 RAV4 HV [12/2021 - ]; BRAKE SYSTEM (OTHER): BRAKE FLUID (w/o Vacuum Brake Booster): BLEEDING](/t3Portal/stylegraphics/info.gif)
(c) Inspect the master cylinder sensor 1, reaction force pressure and servo pressure.
(1) Check the value output from "Master Cylinder Sensor 1", "Reaction Force Pressure" and "Servo Pressure" by depressing the brake pedal.
Chassis > Brake/EPB > Data List
|
Tester Display |
|---|
|
Master Cylinder Sensor 1 |
Chassis > Brake Booster > Data List
|
Tester Display |
|---|
|
Reaction Force Pressure |
|
Servo Pressure |
Standard Result:
for 2WD
|
Pedal Effort |
Reaction Force Pressure (MPa) |
Servo Pressure (MPa) |
Master Cylinder Sensor 1 (MPa) |
Front Right Wheel Hydraulic Pressure |
Front Left Wheel Hydraulic Pressure |
|---|---|---|---|---|---|
|
50 N (5 kgf, 11.2 lbf) |
0 to 0.70 |
1.28 to 5.28 |
0.98 to 4.98 |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
|
100 N (10 kgf, 22.5 lbf) |
0.57 to 1.37 |
5.36 to 9.36 |
5.06 to 9.06 |
5.06 to 9.06 MPa (51.6 to 92.4 kgf/cm2, 734 to 1314 psi) |
5.06 to 9.06 MPa (51.6 to 92.4 kgf/cm2, 734 to 1314 psi) |
|
150 N (15 kgf, 33.7 lbf) |
1.18 to 1.98 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
|
200 N (20 kgf, 45.0 lbf) |
1.87 to 2.67 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
|
Pedal Effort |
Reaction Force Pressure (MPa) |
Servo Pressure (MPa) |
Master Cylinder Sensor 1 (MPa) |
Rear Right Wheel Hydraulic Pressure |
Rear Left Wheel Hydraulic Pressure |
|---|---|---|---|---|---|
|
50 N (5 kgf, 11.2 lbf) |
0 to 0.70 |
1.28 to 5.28 |
0.98 to 4.98 |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
|
100 N (10 kgf, 22.5 lbf) |
0.57 to 1.37 |
5.36 to 9.36 |
5.06 to 9.06 |
5.06 to 9.06 MPa (51.6 to 92.4 kgf/cm2, 734 to 1314 psi) |
5.06 to 9.06 MPa (51.6 to 92.4 kgf/cm2, 734 to 1314 psi) |
|
150 N (15 kgf, 33.7 lbf) |
1.18 to 1.98 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
|
200 N (20 kgf, 45.0 lbf) |
1.87 to 2.67 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
Standard Result:
for AWD
|
Pedal Effort |
Reaction Force Pressure (MPa) |
Servo Pressure (MPa) |
Master Cylinder Sensor 1 (MPa) |
Front Right Wheel Hydraulic Pressure |
Front Left Wheel Hydraulic Pressure |
|---|---|---|---|---|---|
|
50 N (5 kgf, 11.2 lbf) |
0 to 0.70 |
1.28 to 5.28 |
0.98 to 4.98 |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
|
100 N (10 kgf, 22.5 lbf) |
0.57 to 1.37 |
5.58 to 9.58 |
5.28 to 9.28 |
5.28 to 9.28 kPa (53.8 to 94.6 kgf/cm2, 766 to 1346 psi) |
5.28 to 9.28 kPa (53.8 to 94.6 kgf/cm2, 766 to 1346 psi) |
|
150 N (15 kgf, 33.7 lbf) |
1.18 to 1.98 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
|
200 N (20 kgf, 45.0 lbf) |
1.87 to 2.67 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
|
Pedal Effort |
Reaction Force Pressure (MPa) |
Servo Pressure (MPa) |
Master Cylinder Sensor 1 (MPa) |
Rear Right Wheel Hydraulic Pressure |
Rear Left Wheel Hydraulic Pressure |
|---|---|---|---|---|---|
|
50 N (5 kgf, 11.2 lbf) |
0 to 0.70 |
1.28 to 5.28 |
0.98 to 4.98 |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
0.98 to 4.98 MPa (10.0 to 50.8 kgf/cm2, 142 to 722 psi) |
|
100 N (10 kgf, 22.5 lbf) |
0.57 to 1.37 |
5.58 to 9.58 |
5.28 to 9.28 |
5.28 to 9.28 kPa (53.8 to 94.6 kgf/cm2, 766 to 1346 psi) |
5.28 to 9.28 kPa (53.8 to 94.6 kgf/cm2, 766 to 1346 psi) |
|
150 N (15 kgf, 33.7 lbf) |
1.18 to 1.98 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
|
200 N (20 kgf, 45.0 lbf) |
1.87 to 2.67 |
7.30 to 11.3 |
7.00 to 11.00 |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
7.00 to 11.00 MPa (71.4 to 112.1 kgf/cm2, 1015 to 1595 psi) |
(d) Remove the pedal effort gauge and SST.
(1) Remove the pedal effort gauge and SST, and bleed the brake line.
Click here
(e) Inspect the accumulator pressure.
(1) While fully depressing the brake pedal 4 or 5 times, check that the "ECB Motor Relay" changes to ON once or more.
Chassis > Brake Booster > Data List
|
Tester Display |
|---|
|
ECB Motor Relay |
|
Accumulator Pressure |
HINT:
Usually the "ECB Motor Relay" is OFF.
(2) After confirming that the brake booster pump motor stops, check the value output from "Accumulator Pressure".
Standard Result:
15 to 21 MPa
2. INSPECT BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY
(a) Check the auxiliary battery voltage.
Standard Voltage:
11 to 14 V (while the ignition switch is off)
(b) Set a pedal effort gauge and SST.
HINT:
Simultaneously measure the brake fluid pressure of all 4 wheels, or 2 wheels at a time.
|
(1) Set a pedal effort gauge and SST. SST: 09709-29018 09709-00060 |
|
(2) Move the shift lever to P and apply the parking brake.
(3) Clear the DTCs.
(4) Bleed air from SST (LSPV gauge).
Click here
(c) Check operation without brake boost.
(1) Inspect and adjust the brake pedal height.
Click here
|
(2) Adjust the brake fluid level of the reservoir so that it is between the MIN line and fluid level support line. |
|
(3) Select "Motor Deactivate" on the "ECB (Electronically Controlled Brake system) Utility" screen.
Chassis > Brake/EPB > Utility
|
Tester Display |
|---|
|
ECB Utility |
(4) Perform "Motor Deactivate" according to the display on the GTS.
(5) Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.
HINT:
A buzzer may sound due to low accumulator pressure. As this is not a malfunction, continue the procedure.
(6) Check that the brake pedal is firm.
(7) Check the values output from "Stroke Sensor" and "Stroke Sensor2" by depressing the brake pedal.
Chassis > Brake Booster > Data List
|
Tester Display |
|---|
|
Stroke Sensor |
Chassis > Brake/EPB > Data List
|
Tester Display |
|---|
|
Stroke Sensor2 |
Standard Result:
|
Pedal Effort |
Stroke Sensor (V) |
Stroke Sensor2 (V) |
Front Right Wheel Hydraulic Pressure |
Front Left Wheel Hydraulic Pressure |
|---|---|---|---|---|
|
200 N (20 kgf, 45.0 lbf) |
1.45 to 2.15 |
2.85 to 3.55 |
0 to 2.90 MPa (0 to 29.6 kgf/cm2, 0 to 421 psi) |
0 to 2.90 MPa (0 to 29.6 kgf/cm2, 0 to 421 psi) |
|
500 N (51 kgf, 112.4 lbf) |
1.79 to 2.49 |
2.51 to 3.21 |
1.15 to 5.15 MPa (11.7 to 52.5 kgf/cm2, 167 to 747 psi) |
1.15 to 5.15 MPa (11.7 to 52.5 kgf/cm2, 167 to 747 psi) |
|
Pedal Effort |
Stroke Sensor (V) |
Stroke Sensor2 (V) |
Rear Right Wheel Hydraulic Pressure |
Rear Left Wheel Hydraulic Pressure |
|---|---|---|---|---|
|
200 N (20 kgf, 45.0 lbf) |
1.45 to 2.15 |
2.85 to 3.55 |
0 to 2.90 MPa (0 to 29.6 kgf/cm2, 0 to 421 psi) |
0 to 2.90 MPa (0 to 29.6 kgf/cm2, 0 to 421 psi) |
|
500 N (51 kgf, 112.4 lbf) |
1.79 to 2.49 |
2.51 to 3.21 |
1.15 to 5.15 MPa (11.7 to 52.5 kgf/cm2, 167 to 747 psi) |
1.15 to 5.15 MPa (11.7 to 52.5 kgf/cm2, 167 to 747 psi) |
HINT:
Check the performance of the brake booster with master cylinder assembly by comparing the pedal force with the value of the LSPV gauge and each stroke sensor. If there is a problem, determine the state of the brake booster with master cylinder assembly by using these results together with the results from inspecting the brake pedal stroke sensor.
(8) Remove the pedal effort gauge and SST, and bleed the brake system.
Click here
(9) Check the value output from "Accumulator Pressure".
Chassis > Brake Booster > Data List
|
Tester Display |
|---|
|
Accumulator Pressure |
Standard Result:
15 to 21 MPa
(10) Clear the DTCs.
3. INSPECT STROKE SIMULATOR (BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY)
(a) Check the auxiliary battery voltage.
Standard Voltage:
11 to 14 V (while the ignition switch is off)
(b) Set a pedal effort gauge.
(1) Set a pedal effort gauge.
(2) Move the shift lever to P and apply the parking brake.
(3) Clear the DTCs.
(c) Check operation with brake boost.
(1) Depress the brake pedal 4 or 5 times.
(2) Check the values output from "Stroke Sensor" and "Stroke Sensor2" by depressing the brake pedal.
Chassis > Brake Booster > Data List
|
Tester Display |
|---|
|
Stroke Sensor |
Chassis > Brake/EPB > Data List
|
Tester Display |
|---|
|
Stroke Sensor2 |
Standard Voltage:
|
Pedal Effort |
Stroke Sensor (V) |
Stroke Sensor2 (V) |
|---|---|---|
|
50 N (5 kgf, 11.2 lbf) |
1.20 to 1.90 |
3.10 to 3.80 |
|
100 N (10 kgf, 22.5 lbf) |
1.41 to 2.11 |
2.89 to 3.59 |
|
150 N (15 kgf, 33.7 lbf) |
1.60 to 2.30 |
2.70 to 3.40 |
|
|