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Home >> Toyota >> 2021 >> RAV4 XLE, FWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information (2 Of 2) >> BRAKE BOOSTER (w/o Vacuum Brake Booster) >> Installation [11/2018 - 12/2021] >> Procedure

Installation [11/2018 - 12/2021]: Procedure

  1. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster with master cylinder assembly.
  2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Install the brake booster with master cylinder assembly with the 4 nuts.
      GTY921976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 Front No. 2 Brake Tube

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

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not carry the brake booster with master cylinder assembly by the portion shown in the illustration.
      • Be careful not to allow brake fluid to enter the connector of ECU.
      • 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 is filled with brake fluid.
    2. Engage the clamp to install a new brake tube clamp to the No. 4 front brake tube.
      GTY882491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the clamp to install the No. 4 front brake tube with brake tube clamp to the brake line.
      GTY889090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the clamp and install a new brake tube clamp to the vehicle body.
      GTY889089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the 4 clamps to install the brake tube clamp to the brake lines.
    6. Engage the 8 clamps to install the 2 new brake tube clamps to the brake lines.
      GTY882495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Temporarily install each brake line to the correct position on the brake booster with master cylinder assembly as shown in the illustration.
      GTY886004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Front Wheel Cylinder LH
      *b To Rear Wheel Cylinder RH
      *c To Brake Booster Pump Assembly
      *d To Rear Wheel Cylinder LH
      *e To Front Wheel Cylinder RH
    8. Using a union nut wrench, tighten each brake line.
      GTY900509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      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)

    9. Connect the connector to the brake booster with master cylinder assembly.
      GTY890977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the connector
      Lock the lock lever
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the actuator connector can be connected smoothly.
      • Do not allow water, oil or dirt to enter the connector.
    10. Engage the clamp.
  3. CONNECT NO. 4 FRONT BRAKE TUBE 
    1. Using a union nut wrench, connect the No. 4 front brake tube.
      GTY882043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      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)

  4. CONNECT NO. 1 BRAKE ACTUATOR TUBE 
    1. Install the No. 1 brake actuator tube with the 2 nuts.
      GTY935922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

  5. INSTALL RESERVOIR BRACKET 
    1. Temporarily install the reservoir bracket with the bolt and 2 nuts.
    2. Tighten the bolt and 2 nuts in the order shown in the illustration..
      Fig 1: Reservoir Bracket Bolt And Nuts Tightening Sequence
      GTY877101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19 N.m (194 kgf/cm, 168 in.lbf) 

  6. TEMPORARILY INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH RESERVOIR HOSE 
    1. Temporaily install the brake master cylinder reservoir to the reservoir bracket.
  7. CONNECT NO. 1 BRAKE ACTUATOR HOSE 
    1. GTY840053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Identification Mark
      Up

      Connect the No. 1 brake actuator hose to the brake master cylinder reservoir assembly, and slide the clip to secure it.

      NOTE:
      • Make sure to match the identification mark on the No. 1 brake actuator hose and brake master cylinder reservoir assembly.
      • When connecting the No. 1 brake actuator hose, face the identification mark up.
      • Make sure to install the hose to the proper location.
      • Install the clip within the range shown in the illustration.
  8. CONNECT NO. 1 RESERVOIR HOSE 
    1. Connect the No. 1 reservoir hose to the brake booster with master cylinder assembly, and slide the clip to secure it.
      GTY852938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Identification Mark
      Up
      NOTE:
      • Make sure to match the identification mark on the No. 1 reservoir hose and brake booster with master cylinder assembly.
      • When connecting the No. 1 reservoir hose, face the identification mark up.
      • Make sure to install the hose to the proper location.
      • Install the clip within the range shown in the illustration.
  9. CONNECT NO. 2 RESERVOIR HOSE 
    1. Connect the No. 2 reservoir hose to the brake booster with master cylinder assembly, and slide the clip to secure it.
      GTY846299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Identification Mark
      Up
      NOTE:
      • Make sure to match the identification mark on the No. 2 reservoir hose and brake booster with master cylinder assembly.
      • When connecting the No. 2 reservoir hose, face the identification mark up.
      • Make sure to install the hose to the proper location.
      • Install the clip within the range shown in the illustration.
  10. BLEED NO. 1 BRAKE ACTUATOR TUBE 
    1. Add brake fluid into the brake master cylinder reservoir assembly.
    2. Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the No. 1 brake actuator tube.
      GTY875566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Brake Actuator Tube
      NOTE:
      • Do not damage the hoses or tubes.
      • Do not spill brake fluid.
      • Continue this procedure until only a minor amount of air remains in the brake actuator tube.
  11. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Install the brake master cylinder reservoir assembly with the 2 nuts.
      GTY882552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

  12. INSTALL PUSH ROD PIN 

    Refer to PROCEDURE - Step 3

  13. CONNECT WIRE HARNESS 
    1. GTY937398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the connector to the brake pedal stroke sensor assembly.

    2. Engage the 2 clamps to connect the wire harness to the brake pedal support assembly.
  14. INSTALL BRAKE PEDAL RETURN SPRING 

    Refer to PROCEDURE - Step 5

  15. INSTALL STOP LIGHT SWITCH ASSEMBLY 

    Refer to INSTALLATION [11/2018 - ]

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

    Refer to PROCEDURE - Step 7

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

    Refer to PROCEDURE - Step 8

  18. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

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

  19. FILL RESERVOIR WITH BRAKE FLUID 
  20. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 12

  21. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [11/2018 - 12/2021]

  22. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [11/2018 - 12/2021]

  23. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 46 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 54 [02/2019 - 08/2020] , or refer to PROCEDURE - Step 54 [08/2020 - 12/2021]

  24. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [11/2018 - ]

  25. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE AND ZERO POINT OF YAW RATE AND ACCELERATION SENSOR 

    Refer to UTILITY [11/2018 - 02/2019] , or refer to UTILITY [02/2019 - 12/2021]

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