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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Rear) - Service Information (PHEV) >> Rear Brake >> Installation [06/2020 - 10/2022] >> Procedure

Installation [06/2020 - 10/2022]: Procedure

  1. INSTALL REAR DISC 
    1. Align the matchmarks of the rear disc and rear axle hub and bearing assembly, and install the rear disc.
      NOTE:

      When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

      GTY977214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
  2. INSTALL REAR DISC BRAKE CYLINDER MOUNTING 
    1. Install the rear disc brake cylinder mounting to the rear axle carrier sub-assembly with the 2 bolts.

      Torque: 190 N.m (1937 kgf/cm, 140 ft.lbf) 

  3. INSTALL REAR DISC BRAKE BUSHING DUST BOOT 
    1. Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new rear disc brake bushing dust boots.

      HINT: 

      Apply more than 0.3 g (0.01 oz.) of lithium soap base glycol grease to each rear disc brake bushing dust boot.

      GTY851376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium Soap Base Glycol Grease
    2. Install the 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting.
      GTY976209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN 
    1. GTY840429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium Soap Base Glycol Grease

      Apply a light layer of lithium soap base glycol grease to the contact surface of the rear No. 2 disc brake cylinder slide pin.

    2. Install a new rear disc brake cylinder slide bushing to the rear No. 2 disc brake cylinder slide pin.
    3. GTY846659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium Soap Base Glycol Grease

      Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin.

    4. Install the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin to the rear disc brake cylinder mounting.
      GTY976003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear No. 1 Disc Brake Cylinder Slide Pin
      *2 Rear No. 2 Disc Brake Cylinder Slide Pin
    5. Push the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin into each rear disc brake bushing dust boot to engage the pins to the boots.
  5. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE 
    1. Clean the contact surfaces of the rear disc brake pad support plate, rear disc brake cylinder mounting LH and rear disc brake pad with brake cleaner.
    2. Install the 4 rear disc brake pad support plates to the rear disc brake cylinder mounting LH.
      NOTE:
      • Be sure to install the rear disc brake pad support plate in the correct position.
      • When reusing the rear disc brake pad support plate, check the installation position using the identification mark placed when it was removed.
  6. INSTALL REAR DISC BRAKE ANTI-SQUEAL SHIM 

    Refer to PROCEDURE - Step 1

  7. INSTALL REAR DISC BRAKE PAD 
    1. Install the 2 rear disc brake pads to the rear disc brake cylinder mounting.
      NOTE:
      • Keep the friction surfaces of the rear disc brake pads and rear disc free from oil and grease.
      • Install the rear disc brake pad so that the rear disc brake pad wear indicator plate is mounted on the lower side of the vehicle.

      HINT: 

      If the rear disc brake pad has an identification mark, be sure to confirm the installation location.

      GTY976093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Side (Brown)
      *b Outer Side (Purple)
  8. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY 
    1. Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 new bolts in the order shown in the illustration.

      Torque: 34.3 N.m (350 kgf/cm, 25 ft.lbf) 

      Fig 1: Identifying Rear Disc Brake Cylinder Assembly To Rear Disc Brake Cylinder Mount Tightening Procedure
      GTY976975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
  9. INSTALL PARKING BRAKE ACTUATOR ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  10. CONNECT NO. 2 PARKING BRAKE WIRE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  11. CONNECT REAR FLEXIBLE HOSE LH 
    1. Connect the rear flexible hose LH to the rear disc brake cylinder assembly with a new union bolt and a new gasket.

      Torque: 29 N.m (296 kgf/cm, 21 ft.lbf) 

      GTY976047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Install the rear flexible hose LH lock securely into the lock hole in the rear disc brake cylinder assembly.

  12. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    1. Connect the reservoir level switch connector.
    2. Connect the cable to the negative (-) auxiliary battery terminal.

      Refer to INSTALLATION [06/2020 - 10/2022]

    3. When not performing air bleeding:
      1. Turn the ignition switch on (READY).
      2. Depress the brake pedal and release it.
      3. Clear the DTCs.

        Refer to DTC CHECK / CLEAR [06/2020 - ]

  13. BLEED BRAKE LINE 

    Refer to BLEEDING [06/2020 - ]

  14. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY 
    WARNING:

    If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder assembly.

    NOTE:
    • Perform air bleeding while adding brake fluid to maintain the fluid level between the MIN and MAX lines of the reservoir.
    • Keep any painted surface free from brake fluid.

    HINT: 

    • The following procedure is for the LH side.
    • Use the same procedure for the RH side and LH side.
    1. Perform rear disc brake pad replacement mode procedure 5 times.

      Refer to UTILITY [06/2020 - ]

    2. Release the parking brake.
    3. Detach the 3 hooks and disconnect the hood to cowl top seal from the center cowl top ventilator louver.
      GTY977005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Detach the 2 claws and 2 guides and remove the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.
      GTY977006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the brake master cylinder reservoir filler cap assembly.
      GTY976631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Force air within the rear disc brake cylinder assembly to accumulate at the rear disc brake bleeder plug.(*1)
      1. Disable brake control.

        See step  4 [06/2020 - 12/2021], or see step  4 [12/2021 - 10/2022]

      2. Disconnect the No. 2 parking brake wire assembly connector.

        Refer to PROCEDURE - Step 4

      3. Hold the 2 rear disc brake cylinder slide pins and remove the 2 bolts and separate the rear disc brake cylinder assembly from the rear disc brake cylinder mounting.
        GTY976400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Turn
        *b Hold
      4. Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.
        GTY882564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Temporarily install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.
      6. Connect the No. 2 parking brake wire assembly connector.

        Refer to PROCEDURE - Step 2

      7. Connect the reservoir level switch connector.
      8. Connect the cable to the negative (-) auxiliary battery terminal.

        Refer to INSTALLATION [06/2020 - 10/2022]

      9. Turn the ignition switch to ON (READY).
      10. Depress the brake pedal and release it.
      11. Apply the parking brake.
    7. Enter ECB (Electronically Controlled Brake system) Deactivate Mode.(*2)
      NOTE:
      • Performing the following procedure enters ECB (Electronically Controlled Brake system) Deactivate Mode without using the GTS.
      • ECB (Electronically Controlled Brake system) Deactivate Mode allows the brake lines to be bled without using the GTS.
      • The brake warning light blinks (yellow) to indicate that ECB (Electronically Controlled Brake system) Deactivate Mode is selected.
      • Be sure to confirm that the brake warning light is blinking (yellow) throughout the brake line bleeding procedure.
      • If any of the following conditions are met, ECB (Electronically Controlled Brake system) Deactivate Mode is canceled and the brake warning light (yellow) turns off. Do not allow ECB (Electronically Controlled Brake system) Deactivate Mode to be canceled while bleeding the brake lines or DTCs may be stored.
        The shift lever is moved from P to any other position.
        The ignition switch is turned to ON (READY).
        The ignition switch is turned off.
        The parking brake is released.
        The vehicle speed is more than 0 km/h (0 mph).
      • Do not rotate any brake disc while ECB (Electronically Controlled Brake system) Deactivate Mode is selected.
      • Although the brake warning light (yellow) will blink and a buzzer will sound while performing brake line bleeding, this is not a malfunction.
      1. Perform the procedure listed below within 1 minute.
        1. Turn the ignition switch to ON with the shift lever in P and parking brake applied.
        2. Move the shift lever to N and then depress the brake pedal more than 8 times within 5 seconds.
        3. Move the shift lever to P and then depress the brake pedal more than 8 times within 5 seconds.
        4. Move the shift lever to N and then depress the brake pedal more than 8 times within 5 seconds.
        5. Move the shift lever to P.
      2. Check that the brake warning light is blinking (yellow).
        GTY454345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Brake Warning Light (Yellow)
    8. Bleed the brake line.(*3)
      1. Remove the brake master cylinder reservoir filler cap assembly.
        GTY976631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the rear disc brake bleeder plug cap.
      3. Connect a vinyl tube to the rear disc brake bleeder plug.
      4. Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.(*a)
      5. Depress the brake pedal several times with approximately 1 second between each depression, and then loosen the bleeder plug with the pedal depressed.(*b)
      6. When brake fluid stops coming out, tighten the bleeder plug and then release the brake pedal for 1 second or more.(*c)

        HINT: 

        When the brake pedal is released, the piston inside the master cylinder may take longer than the brake pedal to return to its original position. Therefore, make sure to wait for 1 second or more between each depression of the brake pedal.

      7. Repeat steps (*a) through (*c) until there are no signs of air in the brake fluid.
      8. Release the parking brake.
    9. Repeat steps (*1) through (*3) 3 times.
      NOTE:

      If there is still air in the system after performing steps (*1) through (*3) 3 times, repeat the steps (*1) through (*3) until the air has been bled.

    10. Tighten the rear disc brake bleeder plug completely.

      Torque: 8.3 N.m (85 kgf/cm, 73 in.lbf) 

    11. Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.
    12. Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with 2 new bolts.

      Torque: 34.3 N.m (350 kgf/cm, 25 ft.lbf) 

    13. Inspect for brake fluid leaks.
    14. Adjust the brake fluid level in the reservoir.

      Refer to ON-VEHICLE INSPECTION [06/2020 - ]

    15. Install the brake master cylinder reservoir filler cap assembly.
    16. Install the center cowl top ventilator louver.
      1. Engage the 2 claws and 2 guides to install the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.
      2. Engage the 3 hooks and install the hood to cowl top seal from the cowl top ventilator louver sub-assembly.
    17. Turn the ignition switch off.
    18. Clear the DTCs.

      Refer to DTC CHECK / CLEAR [06/2020 - ]

  15. INSTALL REAR WHEEL 

    Refer to INSTALLATION [06/2020 - ]

  16. NORMAL CONDITION RECOVERY 

    Refer to UTILITY [06/2020 - ]

  17. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    Refer to WORK PROCEDURE [06/2020 - 10/2022]

    HINT: 

    When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [06/2020 - 12/2021] , or refer to AUTOMATIC LEARNING CHART [12/2021 - ]

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