BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (w/ Vacuum Brake Booster): REMOVAL; 2023 MY RAV4 RAV4 HV [10/2022

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000026Q65
Model Year Start: 2023	Model: RAV4	Prod Date Range: [10/2022 - 10/2023]
Title: BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (w/ Vacuum Brake Booster): REMOVAL; 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]

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 actuator assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Battery terminal is disconnected/reconnected	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)	Stop and start system
	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for Gasoline model)*
		Pre-collision system
	Reset back door close position	Power back door system (for Gasoline model)
	Back door lock initialization	Power door lock control system
Replacement of brake actuator assembly	Operate the electric parking brake switch assembly	Parking brake indicator light blinks when the engine switch is first turned on (IG)
Replacement of brake actuator assembly	Perform system variant learning and acceleration sensor zero point calibration	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates

NOTICE:

After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.

PROCEDURE

1. PRECAUTION

NOTICE:

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

Click here

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click here

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here

3. DRAIN BRAKE FLUID

NOTICE:

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

4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

5. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY

Click here

6. REMOVE BRAKE ACTUATOR WITH BRACKET

(a) Release the lock lever and disconnect the connector from the brake actuator assembly.

	Release the lock lever
	Disconnect the connector

NOTICE:

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

(b) Use tags or make a memo to identify the places to reconnect the brake lines.

*a	From 1st Chamber of Brake Master Cylinder Sub-assembly
*b	From 2nd Chamber of Brake Master Cylinder Sub-assembly
*c	To Front Wheel Cylinder Assembly RH
*d	To Rear Wheel Cylinder Assembly LH
*e	To Rear Wheel Cylinder Assembly RH
*f	To Front Wheel Cylinder Assembly LH

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.

(d) Disengage the 5 clamps to separate the brake lines from the brake tube clamp.

NOTICE:

Do not kink or damage the brake lines.

(e) Remove the bolt and brake tube clamp.

(f) Remove the 2 bolts, nut and brake actuator with bracket.

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.
Be careful not to allow any brake fluid to enter the connector.
Do not hold the brake actuator assembly by the connector.
Do not drop the brake actuator with bracket when carrying it.

HINT:

Remove the brake actuator with bracket while avoiding the brake lines.

7. REMOVE BRAKE ACTUATOR ASSEMBLY

(a) Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.

NOTICE:

Do not hold the brake actuator assembly by the connector.
Be careful not to allow any brake fluid to enter the connector.
Do not drop the brake actuator assembly when carrying it.

8. REMOVE BRAKE ACTUATOR BRACKET CUSHION

(a) Remove the 3 nuts and separate the brake actuator bracket assembly.

*1	No. 1 Brake Actuator Case Collar
*2	Brake Actuator Bracket Cushion

(b) Remove the 3 No. 1 brake actuator case collars from the brake actuator bracket cushion.