BRAKE SYSTEM (OTHER): BRAKE MASTER CYLINDER (w/ Vacuum Brake Booster): REMOVAL; 2024 MY RAV4 RAV4 HV [10/2023 - ]

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000002FR6F
Model Year Start: 2024	Model: RAV4	Prod Date Range: [10/2023 - ]
Title: BRAKE SYSTEM (OTHER): BRAKE MASTER CYLINDER (w/ Vacuum Brake Booster): REMOVAL; 2024 MY RAV4 RAV4 HV [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 master cylinder sub-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	Link
1: When performing learning using the Techstream. Click here 2: w/o Power Back Door System
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)*1
		Pre-collision system
	Reset back door close position	Power back door system
	Back door lock initialization*2	Power door lock control system

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.
Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

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. REMOVE BATTERY

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 RESERVOIR BRACKET (w/ Stop And Start System)

(a) Remove the bolt, nut and reservoir bracket.

7. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Disengage the clamp and disconnect the connector from the brake master cylinder reservoir assembly.

(b) Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

NOTICE:

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

(c) Remove the 2 nuts and brake master cylinder sub-assembly from the brake booster assembly.

NOTICE:

The brake master cylinder sub-assembly requires careful handling. Do not drop or subject the brake master cylinder sub-assembly to any impact. Do not reuse a brake master cylinder sub-assembly that has been dropped.
Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body when carrying it.
Do not pull out the master cylinder piston.
Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.
When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or with its tip facing downward (the master cylinder piston is facing upward) to prevent the master cylinder piston from falling out.
Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder piston, remove it by using a piece of new and dry cloth. Do not use water or detergent. Then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.
Do not use any other types of grease.
Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

8. REMOVE BRAKE MASTER CYLINDER O-RING

(a) Remove the brake master cylinder O-ring from the brake master cylinder sub-assembly.