Toyota RAV4 Service Manual: Brake booster
Installation (2005/11-2006/01)
- Install check valve grommet
- Install the grommet to the booster.
- Install brake vacuum check valve assembly
- Install the check valve to the grommet.
- Install brake booster gasket
- Install a new gasket to the booster.
- Install brake master cylinder push rod clevis
- Install the push rod clevis to the booster.
- 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.
- Install brake booster assembly
- Install the booster with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*Lbf)
- Install push rod pin
- Apply lithium soap base glycol grease to the push rod pin.
- Install the push rod pin to the push rod clevis.
Notice:
The push rod pin must be installed as shown in the illustration.
- Install the clip to the push rod pin.
Notice:
The clip must be installed as shown in the illustration.
- Check and adjust brake booster push rod (see page br-24)
- Connect vacuum hose
- Connect the vacuum hose to the check valve.
- Install brake master cylinder subassembly (see page br-25)
- Install abs and traction actuator assembly with bracket (see page bc-186)
- Connect brake lines (see page bc-187)
- Fill reservoir with brake fluid (see page br- 6)
- Bleed air from brake master cylinder (see page br-7)
- Bleed air from brake line (see page br-7)
- Bleed air from abs and traction actuator assembly (see page br-8)
- Check and adjust brake pedal height (see page br-13)
- Check brake pedal free play (see page br- 14)
- Check brake pedal reserve distance (see page br-14)
- Check brake fluid level in reservoir (see page br-6)
- Check for brake fluid leakage
- Install air cleaner case sub-assembly
- 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- )
- Install check valve grommet
- Install the grommet to the booster.
- Install brake vacuum check valve assembly
- Install the check valve to the grommet.
- Install brake booster gasket
- Install a new gasket to the booster.
- Install brake master cylinder push rod clevis
- Install the push rod clevis to the booster.
- 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.
- Install brake booster assembly
- Install the booster with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*Lbf)
- Install push rod pin
- Apply lithium soap base glycol grease to the push rod pin.
- Install the push rod pin to the push rod clevis.
Notice:
The push rod pin must be installed as shown in the illustration.
- Install the clip to the push rod pin.
Notice:
The clip must be installed as shown in the illustration.
- Check and adjust brake booster push rod (see page br-24)
- Connect vacuum hose
- Connect the vacuum hose to the check valve.
- Install brake master cylinder subassembly (see page br-26)
- Install abs and traction actuator assembly with bracket (see page bc-187)
- Connect brake lines (see page bc-188)
- Fill reservoir with brake fluid (see page br- 6)
- Bleed air from brake master cylinder (see page br-7)
- Bleed air from brake line (see page br-7)
- Bleed air from abs and traction actuator assembly (see page br-8)
- Check and adjust brake pedal height (see page br-15)
- Check brake pedal free play (see page br- 15)
- Check brake pedal reserve distance (see page br-16)
- Check brake fluid level in reservoir (see page br-6)
- Check for brake fluid leakage
- Install air cleaner case sub-assembly (for 2az-fe)
- 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.
- Install air cleaner case (for 2gr-fe)
- 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:
Diagnostic trouble code chart
Hint:
If no abnormality is found when inspecting parts, check the
skid control ecu and check for poor contact at the ground
points.
If a dtc is displayed during the dtc check, check the
circuit for the dtc listed in the table below. For details of
each dtc, refer to the page indicated. ...
Lost communication with front passenger side - side airbag sensor assembly
Description
The side airbag sensor rh consists of parts including the diagnostic circuit
and the lateral deceleration
sensor.
When the center airbag sensor receives signals from the lateral deceleration
sensor, it determines
whether or not the srs should be activated.
Dtc b1627/82 i ...
Fail-safe chart
If a problem occurs in the electric power steering system, the
p/s warning light will come on in the combination meter and
steering power assist will be stopped, fixed at a particular
point, or decreased simultaneously to protect the system.
Hint:
The amount of power assist may be decreased ...
