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

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000026Q66
Model Year Start: 2023	Model: RAV4	Prod Date Range: [10/2022 - 10/2023]
Title: BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (w/o 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 Procedure After Parts Removed/Installed/Replaced (for HV Model)

Replaced Part or Performed Procedure	Necessary procedures	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Disconnect cable from negative (-) auxiliary battery terminal	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for HV model)*
		Pre-collision system
	Reset back door close position	Power back door system (for HV model)
	Back door lock initialization	Power door lock control system
No. 2 skid control ECU (brake actuator assembly)	Bleed air Perform "Reset Memory" Perform "Calibration"	DTCs are stored ABS warning light illuminates Brake system warning light (yellow indicator) illuminates Slip indicator light illuminates Electronically controlled brake system disabled or malfunctions
No. 2 skid control ECU (brake actuator assembly)	Operate the electric parking brake switch assembly	Parking brake indicator light blinks when the ignition switch is first turned to ON

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 notice before proceeding with work.

Click here

2. PERFORM ACCUMULATOR PRESSURE ZERO DOWN

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

4. REMOVE COWL VENTILATOR SPLASH SHIELD

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) Remove the 2 bolts to separate the brake lines.

*a	From 1st Chamber of Brake Booster with Master Cylinder Assembly
*b	From 2nd Chamber of Brake Booster with Master Cylinder Assembly
*c	To Front Disc Brake Cylinder Assembly RH
*d	To Front Disc Brake Cylinder Assembly LH
*e	To Rear Disc Brake Cylinder Assembly RH
*f	To Rear Disc Brake Cylinder Assembly LH

(d) Using a union nut wrench, disconnect the 6 brake lines from the brake actuator assembly.

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.

(e) Using a union nut wrench, disconnect the front brake tube while holding the front flexible hose with a wrench.

NOTICE:

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

(f) Disengage the clamp and separate the front brake tube.

NOTICE:

Do not kink or damage the front brake tube.

(g) Move aside the front brake tube as shown in the illustration.

NOTICE:

Do not apply excessive force to the front brake tube.

(h) Disengage the clamp and remove the brake tube clamp.

(i) 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 with bracket 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.
Do not drop the brake actuator assembly when carrying it.

8. REMOVE NO. 1 BRAKE ACTUATOR CASE COLLAR

HINT:

Perform this procedure only when replacement of the No. 1 brake actuator case collars is necessary.

(a) Remove the 3 No. 1 brake actuator case collars from the brake actuator bolt cushion.

9. REMOVE BRAKE ACTUATOR BOLT CUSHION

HINT:

Perform this procedure only when replacement of the brake actuator bolt cushions is necessary.

(a) Remove the 3 brake actuator bolt cushions from the brake actuator bracket assembly.