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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/o Vacuum Brake Booster) >> Installation [12/2021 - ] >> Procedure

Installation [12/2021 - ]: Procedure

  1. INSTALL NO. 1 WIRE CLAMP BRACKET 

    HINT: 

    Perform this procedure only when replacement of the No. 1 wire clamp bracket is necessary.

    1. Using a 5 mm long hexagon socket wrench, install the No. 1 wire clamp bracket with the bolt.

      Torque: 6.6 N.m (67 kgf/cm, 58 in.lbf) 

  2. INSTALL NO. 1 RESERVOIR HOSE 

    HINT: 

    Perform this procedure only when replacement of the No. 1 reservoir hose is necessary.

    1. Install the 2 clips to the No. 1 reservoir hose.
    2. Install the No. 1 reservoir hose, and slide the 2 clips to secure it.
      GTY976166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Rib (A)
      *c Rib (B) *d Center of Rib (A)
      *e Center of Rib (B) *f within 40°
      *g within 45° - -
      Front of the Vehicle Left Side of the Vehicle
      NOTE:
      • Make sure to align the paint mark of the reservoir hose with the rib (A).
      • Install the clip within the range shown in the illustration.
  3. INSTALL NO. 2 RESERVOIR HOSE 

    HINT: 

    Perform this procedure only when replacement of the No. 2 reservoir hose is necessary.

    1. Install the 2 clips to the No. 2 reservoir hose.
    2. Install the No. 2 reservoir hose, and slide the 2 clips to secure it.
      GTY976011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Rib (A)
      *c Rib (B) *d Center of Rib (A)
      *e Center of Rib (B) *f within 40°
      *g within 45° - -
      Front of the Vehicle Left Side of the Vehicle
      NOTE:
      • Make sure to align the paint mark of the reservoir hose with the rib (A).
      • Install the clip within the range shown in the illustration.
  4. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake master cylinder gasket to the brake booster with master cylinder assembly.
  5. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Install the brake booster with master cylinder assembly with the 4 nuts.

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

      NOTE:
      • Do not apply excessive force to the brake lines.
      • Be careful not to allow brake fluid to enter the connector.
      • If installing a new brake booster with master cylinder assembly, do not remove the hole plugs before connecting the brake lines because the brake booster with master cylinder assembly is filled with brake fluid.
  6. INSTALL PUSH ROD PIN 

    Refer to PROCEDURE - Step 4

  7. INSTALL BRAKE PEDAL RETURN SPRING 

    Refer to PROCEDURE - Step 5

  8. CONNECT ENGINE ROOM MAIN WIRE 
    1. Engage the 2 clamps to the brake pedal support assembly.
    2. Connect the connector to the brake pedal stroke sensor assembly.
  9. INSTALL STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  10. CONNECT BRAKE LINE 
    1. Engage the 4 clamps to install a new No. 2 brake tube clamp to the brake lines.
      GTY1119370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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 LH
      NOTE:

      Do not kink or damage the brake lines.

    2. Temporarily tighten the 2 brake lines to the brake booster with master cylinder assembly.
      GTY1112459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 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.
    3. Temporarily tighten the 2 brake lines to the correct position on the brake actuator assembly as shown in the illustration.
      GTY1109902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Booster with Master Cylinder Assembly
      *b From 2nd Chamber of Brake Booster with Master Cylinder Assembly
      NOTE:
      • 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.
    4. Install the brake lines with the 2 bolts.
      GTY1112461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    5. Using a union nut wrench, connect the 2 brake lines to the brake booster with master cylinder 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)

      GTY1112297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
    6. 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)

      GTY1114081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
    7. GTY1116577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Front Disc Brake Cylinder Assembly LH
      *b To Rear Disc Brake Cylinder Assembly RH
      *c To Rear Disc Brake Cylinder Assembly LH

      Temporarily tighten the 3 brake lines to the correct position on the brake actuator assembly as shown in the illustration.

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.
    8. Using a union nut wrench, connect the 3 brake lines to the brake actuator assembly.

      Specified tightening torque 

      Torque: 15.2 N.m (155 kgf/cm, 11 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 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.4 N.m (137 kgf/cm, 10 ft.lbf)

      GTY1110661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
  11. CONNECT ENGINE ROOM MAIN WIRE 
    1. Engage the clamp to the brake booster with master cylinder assembly.
      GTY1113166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the connector
      Lock the lock lever
    2. Connect the connector to the brake booster with master cylinder assembly and lock the lock lever.
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the connector can be connected smoothly.
      • Do not allow water, oil or dirt to enter the connector.
    3. Connect the brake fluid level warning switch connector.
    4. Connect the connector to the brake booster with master cylinder assembly.
      NOTE:

      Do not allow water, oil or dirt to enter the connector.

  12. INSTALL ECM 

    Refer to INSTALLATION [08/2020 - ]

  13. FILL RESERVOIR WITH BRAKE FLUID 
  14. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to INSTALLATION [08/2020 - ]

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [12/2021 - 10/2022] , or refer to INITIALIZATION [10/2022 - 10/2023] , or refer to INITIALIZATION [10/2023 - ]

  15. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [12/2021 - ]

  16. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [12/2021 - ]

  17. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to REMOVAL [12/2021 - 10/2022] , or refer to REMOVAL [10/2022 - 10/2023] , or refer to REMOVAL [10/2023 - ]

  18. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 55 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 54 [10/2022 - ]

  19. INSTALL COWL VENTILATOR SPLASH SHIELD 

    Refer to PROCEDURE - Step 2

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [11/2018 - ]

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

    Refer to PROCEDURE - Step 7

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

    Refer to PROCEDURE - Step 8

  23. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to INSTALLATION [08/2020 - ]

  24. PERFORM INITIALIZATION AND CALIBRATION 

    Refer to REMOVAL [12/2021 - 10/2022] , or refer to REMOVAL [10/2022 - 10/2023] , or refer to REMOVAL [10/2023 - ] 

  25. CHECK AND CLEAR DTC 

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

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