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Home >> Toyota >> 2021 >> RAV4 XLE, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information (2 Of 2) >> BRAKE BOOSTER (w/ Vacuum Brake Booster) >> Installation [11/2018 - ] >> Procedure

Installation [11/2018 - ]: Procedure

  1. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assembly.
  2. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Temporarily install the brake booster assembly to the vehicle body.
      NOTE:

      Do not apply excessive force to the brake lines.

    2. Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.
      NOTE:

      Tighten the lock nut when adjusting the brake pedal height.

    3. Install the 4 nuts to secure the brake booster assembly.

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

    4. Install a new brake tube clamp to the vehicle body with the bolt.

      Torque: 7.0 N.m (71 kgf/cm, 62 in.lbf) 

      GTY934209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the clamp and install a new brake tube clamp to the vehicle body.
    6. GTY884597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly

      Temporarily install each brake line to the correct position on the brake actuator assembly as shown in the illustration.

      NOTE:
      • Do not kink or damage the brake line.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.
    7. Engage the 3 clamps to connect the brake tube clamp to the brake lines.
      GTY934210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Engage the 5 clamps to install a new brake tube clamp to the brake lines.
      GTY874720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. GTY874716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Engage the 5 clamps to install a new brake tube clamp to the brake lines.

    10. GTY874715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Engage the 5 clamps to connect the brake tube clamp to the brake lines.

    11. Using a union nut wrench, connect the 2 brake lines to the brake actuator assembly.

      Specified tightening torque 

      Torque: 19.5 N.m (199 kgf/cm, 14 ft.lbf) 

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [11/2018 - ]

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.4 N.m (177 kgf/cm, 13 ft.lbf)

      GTY917096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
    12. w/ Stop and Start System:
      GTY874729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the connector to the vacuum sensor assembly.
    13. Connect the connector to the vacuum warning switch assembly.
      GTY874723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the protective tape.
    15. Engage the guide and connect the wire harness.
      GTY868281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. Install the bolt (A) and nut (B) to secure the wire harness.

      Bolt (A) 

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      Nut (B) 

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

  3. INSTALL CHECK VALVE TO CONNECTOR TUBE HOSE 
    1. Connect the check valve to connector tube hose to the brake booster assembly and slide the clip to secure it.
      GTY923305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      NOTE:
      • When connecting the check valve to connector tube hose, face the paint mark up.
      • Make sure that the tabs of the clip are facing upward.
  4. INSTALL PUSH ROD PIN 

    Refer to PROCEDURE - Step 3

  5. CONNECT WIRE HARNESS 
    1. Engage the 2 clamps to connect the wire harness to the brake pedal support assembly.
      GTY874562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector.
  6. INSTALL BRAKE PEDAL RETURN SPRING 

    Refer to PROCEDURE - Step 5 [11/2018 - 12/2021] , or refer to PROCEDURE - Step 5 [12/2021 - ]

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

    Refer to PROCEDURE - Step 7

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

    Refer to PROCEDURE - Step 8

  9. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to INSTALLATION [11/2018 - 08/2020] , or refer to INSTALLATION [08/2020 - ]

  10. INSTALL BATTERY CLAMP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 71 [11/2018 - 08/2020] , or refer to PROCEDURE - Step 71 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 71 [12/2021 - ]

  11. INSTALL ECM 

    Refer to INSTALLATION [11/2018 - 08/2020] , or refer to INSTALLATION [08/2020 - ]

  12. INSTALL BATTERY 

    Refer to INSTALLATION [11/2018 - 10/2023] , or refer to INSTALLATION [10/2023 - ]

  13. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY 

    Refer to INSTALLATION [11/2018 - ]

  14. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [11/2018 - 12/2021] , or refer to ADJUSTMENT [12/2021 - ]

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