Toyota RAV4 manuals

Toyota RAV4 Service Manual: Brake booster

Toyota RAV4 Service Manual / Brake / Brake booster

Installation (2005/11-2006/01)

  1. Install check valve grommet

  1. Install the grommet to the booster.
  1. Install brake vacuum check valve assembly

  1. Install the check valve to the grommet.
  1. Install brake booster gasket

  1. Install a new gasket to the booster.
  1. Install brake master cylinder push rod clevis

  1. Install the push rod clevis to the booster.
  2. Temporarily tighten the push rod clevis lock nut.

Hint:

The push rod clevis lock nut will be tightened to a torque specification in the "check and adjust brake pedal height" procedures.

  1. Install brake booster assembly

  1. Install the booster with the 4 nuts.

    Torque: 12.7 N*m (130 kgf*cm, 9 ft.*Lbf)

  1. Install push rod pin

Toyota RAV4. Install push rod pin


Toyota RAV4. Install push rod pin


  1. Apply lithium soap base glycol grease to the push rod pin.
  2. Install the push rod pin to the push rod clevis.

Notice:

The push rod pin must be installed as shown in the illustration.

  1. Install the clip to the push rod pin.

Notice:

The clip must be installed as shown in the illustration.

  1. Check and adjust brake booster push rod (see page br-24)

  2. Connect vacuum hose

  1. Connect the vacuum hose to the check valve.
  1. Install brake master cylinder subassembly (see page br-25)

  2. Install abs and traction actuator assembly with bracket (see page bc-186)

  3. Connect brake lines (see page bc-187)

  4. Fill reservoir with brake fluid (see page br- 6)

  5. Bleed air from brake master cylinder (see page br-7)

  6. Bleed air from brake line (see page br-7)

  7. Bleed air from abs and traction actuator assembly (see page br-8)

  8. Check and adjust brake pedal height (see page br-13)

  9. Check brake pedal free play (see page br- 14)

  10. Check brake pedal reserve distance (see page br-14)

  11. Check brake fluid level in reservoir (see page br-6)

  12. Check for brake fluid leakage

  13. Install air cleaner case sub-assembly

  1. Install the air cleaner case (see page em-105).

Hint:

Refer to the procedures from the installation of the air cleaner case up until the installation of the purge vsv.

Installation (2006/01- )

  1. Install check valve grommet

  1. Install the grommet to the booster.
  1. Install brake vacuum check valve assembly

  1. Install the check valve to the grommet.
  1. Install brake booster gasket

  1. Install a new gasket to the booster.
  1. Install brake master cylinder push rod clevis

  1. Install the push rod clevis to the booster.
  2. Temporarily tighten the push rod clevis lock nut.

Hint:

The push rod clevis lock nut will be tightened to a torque specification in the "check and adjust brake pedal height" procedures.

  1. Install brake booster assembly

  1. Install the booster with the 4 nuts.

    Torque: 12.7 N*m (130 kgf*cm, 9 ft.*Lbf)

  1. Install push rod pin

Toyota RAV4. Install push rod pin


Toyota RAV4. Install push rod pin


  1. Apply lithium soap base glycol grease to the push rod pin.
  2. Install the push rod pin to the push rod clevis.

Notice:

The push rod pin must be installed as shown in the illustration.

  1. Install the clip to the push rod pin.

Notice:

The clip must be installed as shown in the illustration.

  1. Check and adjust brake booster push rod (see page br-24)

  2. Connect vacuum hose

  1. Connect the vacuum hose to the check valve.
  1. Install brake master cylinder subassembly (see page br-26)

  2. Install abs and traction actuator assembly with bracket (see page bc-187)

  3. Connect brake lines (see page bc-188)

  4. Fill reservoir with brake fluid (see page br- 6)

  5. Bleed air from brake master cylinder (see page br-7)

  6. Bleed air from brake line (see page br-7)

  7. Bleed air from abs and traction actuator assembly (see page br-8)

  8. Check and adjust brake pedal height (see page br-15)

  9. Check brake pedal free play (see page br- 15)

  10. Check brake pedal reserve distance (see page br-16)

  11. Check brake fluid level in reservoir (see page br-6)

  12. Check for brake fluid leakage

  13. Install air cleaner case sub-assembly (for 2az-fe)

  1. Install the air cleaner case (see page em-105).

Hint:

Refer to the procedures from the installation of the air cleaner case up until the installation of the purge vsv.

  1. Install air cleaner case (for 2gr-fe)

  1. Install the air cleaner case (see page em-31).

Hint:

Refer to the procedures from the installation of the air cleaner case up until the installation of the air cleaner cap sub-assembly.

Brake master cylinder
Components On-vehicle inspection Check brake fluid level warning switch Remove the reservoir filler cap and strainer. Disconnect the brake fluid level warning switch connector. ...

Front brake
Components Removal Hint: Use the same procedures for the lh side and rh side. The procedures listed below are for the lh side. Remove front wheel Drain brake fluid Notic ...

Other materials:

Dtc check / clear
Check dtc Connect the intelligent tester (with can vim) to the dlc3. Turn the ignition switch on and turn the intelligent tester on. Read the dtc by following the prompts on the tester screen. Hint: Refer to the intelligent tester operator's manual for further details. ...

Freeze frame data
Freeze frame data Notice: It is difficult to show the specified values (judgment values) clearly because freeze frame data values change significantly due to differences in measurement conditions, surroundings, or vehicle conditions. For this reason, there may be a problem even w ...

Reporting safety defects for u.S. Owners
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the national highway traffic safety administration (nhtsa) in addition to notifying toyota motor sales, u.S.A., Inc. (Toll-free: 1-800-331-4331). If nhtsa re ...

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