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Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information (1 Of 2) >> BRAKE PEDAL (w/o Vacuum Brake Booster) >> Installation [12/2021 - ] >> Procedure

Installation [12/2021 - ]: Procedure

  1. INSTALL BRAKE PEDAL PAD 
    1. Install the brake pedal pad to the brake pedal support assembly.

      HINT: 

      Installation is easier after applying a small amount of soapy water.

  2. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER 
    1. Engage the 2 claws to install the stop light switch mounting adjuster.
  3. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY 
    1. Temporarily install the brake pedal support assembly with the 2 new clips while avoiding the stud bolts of the brake booster with master cylinder assembly and brake booster support base.
      NOTE:

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

    2. Install the brake pedal support assembly with the bolt and 4 nuts.

      Bolt 

      Torque: 15 N.m (153 kgf/cm, 11 ft.lbf) 

      Nut 

      Torque: 12.7 N.m (130 kgf/cm, 9 ft.lbf) 

  4. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the push rod pin.
      GTY759014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium Soap Base Glycol Grease
    2. Connect the master cylinder push rod clevis to the brake pedal support assembly with the push rod pin, and install a new clip as shown in the illustration.
      GTY1112384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to install the push rod pin in the correct direction.

  5. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring to the brake pedal support assembly as shown in the illustration.
      GTY1109891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front of the Vehicle
      NOTE:

      Be sure to install the brake pedal return spring in the correct direction.

  6. CONNECT ENGINE ROOM MAIN WIRE 
    1. Engage the 2 clamps to install the engine room main wire to the brake pedal support assembly.
  7. INSTALL STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 2

  8. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  9. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

    HINT: 

    It is necessary to connect the cable to the negative (-) auxiliary battery terminal in order to perform the brake pedal inspection and adjustment.

  10. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [12/2021 - ] 

  11. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 5 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 5 [10/2022 - 10/2023] , or refer to PROCEDURE - Step 5 [10/2023 - ]

  12. INSTALL NO. 1 AIR DUCT (for TMC Made) 

    Refer to PROCEDURE - Step 7

  13. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMC Made) 

    Refer to PROCEDURE - Step 8

  14. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to INSTALLATION [08/2020 - ]

  15. PERFORM CALIBRATION 

    Refer to UTILITY [12/2021 - ]

  16. CHECK AND CLEAR DTC 

    Refer to DTC CHECK / CLEAR [12/2021 - ]

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