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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) >> Removal [10/2022 - 10/2023] >> Procedure

Removal [10/2022 - 10/2023]: Procedure

  1. PRECAUTION 
    WARNING:

    Be sure to read precaution thoroughly before servicing.

    Refer to PRECAUTION [08/2020 - ]

    GTY824211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2018 - ]

  2. PERFORM ACCUMULATOR PRESSURE ZERO DOWN 
    1. Using the GTS, perform the accumulator pressure zero down operation.
      1. Select "Motor Deactivate" on the "ECB Utility" screen.

        Chassis > Brake/EPB > Utility 

        Tester Display
        ECB Utility
      2. Perform "Motor Deactivate" according to the display on the GTS.
      3. Select "ECB Deactivate" on the "ECB Utility" screen.

        Chassis > Brake/EPB > Utility 

        Tester Display
        ECB Utility
      4. Perform "ECB Deactivate" according to the display on the GTS.
      5. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

        HINT: 

        A buzzer may sound due to low accumulator pressure. As this is not a malfunction, continue the procedure.

      6. Check that the brake pedal is firm.
        NOTE:

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down operation is not complete.

      7. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Refer to REMOVAL [10/2022 - 10/2023]

    2. When the accumulator pressure zero down could not be performed using the GTS.
      NOTE:

      If DTCs are output, the accumulator pressure zero down operation may not be complete. In this case, perform the following procedure.

      1. With the ignition switch off, disconnect the brake booster with master cylinder assembly connector.
        GTY975804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Be careful not to allow any brake fluid to enter the connector.

      2. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.
      3. Check that the brake pedal is firm.
        NOTE:

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down operation is not complete.

      4. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Refer to REMOVAL [10/2022 - 10/2023]

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2018 - ]

  4. REMOVE COWL VENTILATOR SPLASH SHIELD 

    Refer to PROCEDURE - Step 9

  5. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  6. REMOVE ECM 

    Refer to REMOVAL [10/2022 - 10/2023]

  7. DRAIN BRAKE FLUID 
    NOTE:

    If brake fluid leaks onto any painted surface, immediately wash it off.

  8. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Disconnect the connector from the brake booster with master cylinder assembly.
      GTY975804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the brake fluid level warning switch connector.
      GTY1112462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the lock lever and disconnect the connector from the brake booster with master cylinder assembly.
      GTY1117611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release the lock lever
      Disconnect the connector
      NOTE:

      Be careful not to allow any brake fluid to enter the connector.

    4. Disengage the clamp to separate the engine room main wire from the brake booster with master cylinder assembly.
  9. DISCONNECT BRAKE LINE 
    1. Using a union nut wrench, disconnect the 2 brake lines from 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.
    2. Use tags or make a memo to identify the places to reconnect the brake lines.
      GTY1113242Courtesy 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
      *d To Rear Disc Brake Cylinder Assembly RH
      *e To Rear Disc Brake Cylinder Assembly LH
    3. Using a union nut wrench, disconnect the 5 brake lines from the brake actuator assembly.
      GTY1118332Courtesy 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.
    4. Remove the 2 bolts to separate the brake lines.
      GTY1112461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the 4 clamps to remove the No. 2 brake tube clamp from the brake lines.
      GTY1113109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not kink or damage the brake lines.

  10. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY 

    Refer to REMOVAL [10/2022 - 10/2023]

  11. REMOVE NO. 1 AIR DUCT (for TMC Made) 

    Refer to PROCEDURE - Step 19

  12. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMC Made) 

    Refer to PROCEDURE - Step 20

  13. REMOVE STOP LIGHT SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 2

  14. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Disconnect the connector from the brake pedal stroke sensor assembly.
      GTY1119421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to separate the engine room main wire from the brake pedal support assembly.
  15. REMOVE BRAKE PEDAL RETURN SPRING 

    Refer to PROCEDURE - Step 8

  16. REMOVE PUSH ROD PIN 

    Refer to PROCEDURE - Step 9

  17. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Remove the 4 nuts and brake booster with master cylinder assembly.
      NOTE:
      • Do not apply excessive force to the brake lines.
      • Be careful not to allow any brake fluid to enter the connector.
      GTY1118462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE BRAKE BOOSTER GASKET 
  19. REMOVE NO. 2 RESERVOIR HOSE 

    HINT: 

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

    1. Slide the 2 clips and remove the No. 2 reservoir hose.
      GTY975440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 clips from the No. 2 reservoir hose.
  20. REMOVE NO. 1 RESERVOIR HOSE 

    HINT: 

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

    1. Slide the 2 clips and remove the No. 1 reservoir hose.
      GTY975442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 clips from the No. 1 reservoir hose.
  21. REMOVE 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, remove the bolt and No. 1 wire clamp bracket.
      GTY976803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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