Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001GILA
Model Year Start: 2019 Model: RAV4 Prod Date Range: [11/2018 - 12/2021]
Title: BRAKE SYSTEM (OTHER): BRAKE SYSTEM (w/o Vacuum Brake Booster): ON-VEHICLE INSPECTION; 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

NOTICE:

DTCs may be stored during the inspection procedure. Be sure to clear the DTCs and check that no DTCs are output after the inspection is finished.

PROCEDURE

1. INSPECT PRESSURE SENSOR

(a) Check auxiliary battery voltage.

Standard Voltage:

11 to 14 V (while the power switch is off)

(b) Set a pedal effort gauge, SST and connect the Techstream.

(1) Set a pedal effort gauge and SST.

SST: 09709-29018

09709-00060

09709-00080

*a

Pedal Effort Gauge

*b

SST (LSPV Gauge)

*c

SST (No. 1 Nipple)

(2) Connect the Techstream to the DLC3 with the power switch off, park (P) selected and parking brake applied.

(3) Turn the power switch on (IG) and turn the Techstream on.

(4) Bleed air from SST (LSPV gauge).

Click here 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; BRAKE SYSTEM (OTHER): BRAKE FLUID (w/o Vacuum Brake Booster): BLEEDING+

(c) Inspect the wheel cylinder pressure sensor and regulator pressure sensor.

(1) Enter the following menus: Chassis / ABS/VSC/TRAC / Active Test / Power Supply Air Bleeding Pattern 1.

Chassis > ABS/VSC/TRAC > Active Test

Active Test Display

Power Supply Air Bleeding Pattern1

Data List Display

Regulator Pressure Sensor Output

Wheel Cylinder Pressure Sensor

(2) Select "Wheel Cylinder Pressure Sensor" and "Regulator Pressure Sensor Output".

(3) Check the value output from "Wheel Cylinder Pressure Sensor" and "Regulator Pressure Sensor Output" by depressing the brake pedal.

Standard Result:

Pedal Effort

Regulator Pressure Sensor Output

(V)

Rear Right Wheel Hydraulic Pressure

Rear Left Wheel Hydraulic Pressure

50 N (5 kgf, 11.2 lbf)

0.60 to 1.40

0.46 to 4.46 MPa (4.7 to 45.4 kgf/cm2, 67 to 646 psi)

0.46 to 4.46 MPa (4.7 to 45.4 kgf/cm2, 67 to 646 psi)

100 N (10 kgf, 22.5 lbf)

1.60 to 2.40

5.33 to 9.33 MPa (54.4 to 95.1 kgf/cm2, 773 to 1352 psi)

5.33 to 9.33 MPa (54.4 to 95.1 kgf/cm2, 773 to 1352 psi)

150 N (15 kgf, 33.7 lbf)

2.59 to 3.39

10.19 to 14.19 MPa (104.0 to 144.6 kgf/cm2, 1478 to 2057 psi)

10.19 to 14.19 MPa (104.0 to 144.6 kgf/cm2, 1478 to 2057 psi)

200 N (20 kgf, 45.0 lbf)

3.58 to 4.38

15.06 to 19.06 MPa (153.6 to 194.3 kgf/cm2, 2184 to 2763 psi)

15.06 to 19.06 MPa (153.6 to 194.3 kgf/cm2, 2184 to 2763 psi)

Standard Result:

Pedal Effort

Wheel Cylinder Pressure Sensor

(V)

Front Right Wheel Hydraulic Pressure

Front Left Wheel Hydraulic Pressure

50 N (5 kgf, 11.2 lbf)

0.53 to 1.33

0.11 to 4.11 MPa (1.2 to 41.9 kgf/cm2, 16 to 595 psi)

0.11 to 4.11 MPa (1.2 to 41.9 kgf/cm2, 16 to 595 psi)

100 N (10 kgf, 22.5 lbf)

1.38 to 2.18

4.27 to 8.27 MPa (43.6 to 84.3 kgf/cm2, 620 to 1199 psi)

4.27 to 8.27 MPa (43.6 to 84.3 kgf/cm2, 620 to 1199 psi)

150 N (15 kgf, 33.7 lbf)

2.23 to 3.03

8.44 to 12.44 MPa (86.1 to 126.8 kgf/cm2, 1224 to 1803 psi)

8.44 to 12.44 MPa (86.1 to 126.8 kgf/cm2, 1224 to 1803 psi)

200 N (20 kgf, 45.0 lbf)

3.07 to 3.87

12.57 to 16.57 MPa (128.2 to 168.9 kgf/cm2, 1823 to 2402 psi)

12.57 to 16.57 MPa (128.2 to 168.9 kgf/cm2, 1823 to 2402 psi)

(4) After inspection, turn "Power Supply Air Bleeding Pattern 1" off.

(d) Remove the pedal effort gauge and SST.

(1) Remove the pedal effort gauge and SST, and bleed brake line.

Click here 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; BRAKE SYSTEM (OTHER): BRAKE FLUID (w/o Vacuum Brake Booster): BLEEDING+

(e) Inspect the accumulator sensor.

(1) Enter the following menus: Chassis / ABS/VSC/TRAC / Data List / Accumulator Sensor.

Chassis > ABS/VSC/TRAC > Data List

Tester Display

Accumulator Sensor

(2) Depress the brake pedal 4 or 5 times and operate the booster pump motor.

(3) After confirming that the booster pump motor stops, check the output voltage.

Standard Voltage:

2.9 to 4.2 V

2. INSPECT BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) Check auxiliary battery voltage.

Standard Voltage:

11 to 14 V (while the power switch is off)

(b) Connect the Techstream and set a pedal effort gauge.

(1) Set a pedal effort gauge.

(2) Connect the Techstream to the DLC3 with the power switch off, park (P) selected and parking brake applied.

(3) Turn the power switch on (IG) and turn the Techstream on.

(4) Clear the DTCs.

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): DTC CHECK / CLEAR 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): DTC CHECK / CLEAR

(c) Check operation without the brake booster.

(1) Inspect and adjust the brake pedal height.

Click here 2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/o Vacuum Brake Booster): ADJUSTMENT

(2) Adjust the brake fluid level in the reservoir between MIN line and fluid level support line.

*a

Fluid Level Support Line

*b

MIN Line

(3) Turn the Techstream on and enter the following menus: Chassis / ABS/VSC/TRAC / Utility / ECB (Electronically Controlled Brake system) Utility / Zero Down.

Chassis > ABS/VSC/TRAC > Utility

Tester Display

ECB Utility

NOTICE:

Go to the next step without turning the power switch off.

(4) Enter the following menus: Chassis / ABS/VSC/TRAC / Data List / Wheel Cylinder Pressure Sensor, Stroke Sensor and Stroke Sensor 2.

Chassis > ABS/VSC/TRAC > Data List

Tester Display

Stroke Sensor

Stroke Sensor2

Wheel Cylinder Pressure Sensor

(5) Check the values output from "Wheel Cylinder Pressure Sensor", "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.

Standard Voltage:

Pedal Effort

Wheel Cylinder Pressure Sensor

(V)

Stroke Sensor

(V)

Stroke Sensor 2

(V)

200 N (20 kgf, 45.0 lbf)

0.52 to 1.32

1.19 to 1.89

3.11 to 3.81

500 N (51 kgf, 112.4 lbf)

1.16 to 1.96

1.51 to 2.21

2.79 to 3.49

(6) Turn the power switch off to finish "Zero Down".

(7) Turn the power switch on (IG) and wait for 20 seconds, then enter the following menus: Chassis / ABS/VSC/TRAC / Data List / Accumulator Sensor, and check the output voltage.

Chassis > ABS/VSC/TRAC > Data List

Tester Display

Accumulator Sensor

Standard Voltage:

2.9 to 4.2 V

3. INSPECT STROKE SIMULATOR

(a) Check auxiliary battery voltage.

Standard Voltage:

11 to 14 V (while the power switch is off)

(b) Connect the Techstream and set a pedal effort gauge.

(1) Set a pedal effort gauge.

(2) Connect the Techstream to the DLC3 with the power switch off, park (P) selected and parking brake applied.

(3) Turn the power switch on (IG) and turn the Techstream on.

(4) Clear the DTCs.

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): DTC CHECK / CLEAR 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o Vacuum Brake Booster): DTC CHECK / CLEAR

(c) Check operation with the brake booster.

(1) Turn the power switch on (IG).

(2) Enter the following menus: Chassis / ABS/VSC/TRAC / Data List / Stroke Sensor and Stroke Sensor 2.

Chassis > ABS/VSC/TRAC > Data List

Tester Display

Stroke Sensor

Stroke Sensor2

(3) Depress the brake pedal 4 or 5 times.

(4) Check the values output from "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.

Standard Voltage:

Pedal Effort

Stroke Sensor

(V)

Stroke Sensor 2

(V)

50 N (5 kgf, 11.2 lbf)

1.37 to 2.07

2.93 to 3.63

100 N (10 kgf, 22.5 lbf)

1.66 to 2.36

2.64 to 3.34

150 N (15 kgf, 33.7 lbf)

1.83 to 2.53

2.47 to 3.17