Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM1000000026Q6B
Model Year Start: 2023 Model: RAV4 Prod Date Range: [10/2022 - 10/2023]
Title: BRAKE SYSTEM (OTHER): BRAKE PEDAL (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 pedal support 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

Link
*1: When performing learning using the Techstream.

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

*2: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation.

Disconnect cable from negative (-) auxiliary battery terminal

Perform steering sensor zero point calibration

Lane control system

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system (for HV model)*1

Pre-collision system

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 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

Brake pedal*2
  1. Perform "Reset Memory"
  2. Perform "Calibration"
  • DTCs are stored
  • ABS warning light illuminates
  • Brake system warning light (yellow indicator) illuminates
  • Slip indicator light illuminates
  • Brake control disabled or malfunctions (brake drag, etc.)

2022 - 2024 MY RAV4 RAV4 HV [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 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.
  • 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. (w/o vacuum brake booster)

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read precaution thoroughly before servicing.

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; SUPPLEMENTAL RESTRAINT SYSTEMS: AIRBAG 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 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; SUPPLEMENTAL RESTRAINT SYSTEMS: KNEE AIRBAG ASSEMBLY: REMOVAL

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

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+

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

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+

5. REMOVE BRAKE PEDAL STROKE SENSOR ASSEMBLY

Click here 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE PEDAL STROKE SENSOR (w/o Vacuum Brake Booster): REMOVAL+

6. REMOVE STOP LIGHT SWITCH ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; LIGHTING (EXT): STOP LIGHT SWITCH: REMOVAL+

7. REMOVE ENGINE ROOM MAIN WIRE

(a) Disengage the 2 clamps to separate the engine room main wire from the brake pedal support assembly.

8. REMOVE BRAKE PEDAL RETURN SPRING

(a) Remove the brake pedal return spring from the brake pedal support assembly.

9. REMOVE PUSH ROD PIN

(a) Remove the clip and push rod pin to separate the master cylinder push rod clevis from the brake pedal support assembly.

10. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY

(a) Remove the 2 clips.

(b) Remove the bolt and 4 nuts and push the brake booster with master cylinder assembly toward the engine compartment.

NOTICE:

  • Do not apply excessive force to the brake lines.
  • Do not apply excessive force to the wire harness.

(c) Remove the brake pedal support assembly while avoiding the stud bolts of the brake booster with master cylinder assembly and brake booster support base.

NOTICE:

Be careful not to deform the bracket of the instrument panel reinforcement assembly.

11. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER

(a) Disengage the 2 claws and remove the stop light switch mounting adjuster.

12. REMOVE BRAKE PEDAL PAD

(a) Remove the brake pedal pad from the brake pedal support assembly.