Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001GILC
Model Year Start: 2019 Model: RAV4 Prod Date Range: [11/2018 - 10/2019]
Title: BRAKE SYSTEM (OTHER): BRAKE BOOSTER (w/ Vacuum Brake Booster): REMOVAL; 2019 MY RAV4 RAV4 HV [11/2018 - 10/2019]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during brake booster assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedures

Necessary Procedures

Effect/Inoperative Function When Necessary Procedures are not Performed

Link
*: When performing learning using the Techstream.

Click here 2019 - 2022 MY RAV4 [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for Gasoline Model): CALIBRATION

Battery terminal is disconnected/reconnected

Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

Stop and start system

2019 - 2021 MY RAV4 [11/2018 - 12/2021]; STOP AND START: STOP AND START SYSTEM: PRECAUTION

Perform steering sensor zero point calibration

Lane control system

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system (for Gasoline model)*

Pre-collision system

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system (for Gasoline model)

2019 - 2022 MY RAV4 [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for Gasoline Model): INITIALIZATION

Reset back door close position

Power back door system (for Gasoline model)

2019 - 2023 MY RAV4 [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for Gasoline Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

NOTICE:

  • After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) battery terminal.
  • Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

Waiting Time before Disconnecting Cable from Negative (-) Battery Terminal

System Name

See Procedure

Vehicle enrolled in Toyota Entune system or safety connect system

6 minutes

Vehicle not enrolled in Toyota Entune system and safety connect system

1 minute

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read precaution thoroughly before servicing.

  • w/ Occupant Classification System:

    Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; SUPPLEMENTAL RESTRAINT SYSTEMS: AIRBAG SYSTEM (w/ Occupant Classification System): PRECAUTION 2019 - 2020 MY RAV4 RAV4 HV [02/2019 - 08/2020]; SUPPLEMENTAL RESTRAINT SYSTEMS: AIRBAG SYSTEM (w/ Occupant Classification System): PRECAUTION

  • w/o Occupant Classification System:

    Click here 2019 - 2020 MY RAV4 RAV4 HV [11/2018 - 08/2020]; SUPPLEMENTAL RESTRAINT SYSTEMS: AIRBAG SYSTEM (w/o Occupant Classification System): PRECAUTION

NOTICE:

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.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 10/2019]; BRAKE SYSTEM (OTHER): BRAKE MASTER CYLINDER (w/ Vacuum Brake Booster): REMOVAL

3. REMOVE ECM

Click here 2019 - 2020 MY RAV4 [11/2018 - 08/2020]; A25A-FKS (ENGINE CONTROL): ECM: REMOVAL

4. REMOVE BATTERY CLAMP SUB-ASSEMBLY

Click here 2019 MY RAV4 [11/2018 - 10/2019]; A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; SUPPLEMENTAL RESTRAINT SYSTEMS: KNEE AIRBAG ASSEMBLY: REMOVAL 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; SUPPLEMENTAL RESTRAINT SYSTEMS: KNEE AIRBAG ASSEMBLY: REMOVAL

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

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+ 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+

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

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+ 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL+

8. REMOVE STOP LIGHT SWITCH ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; LIGHTING (EXT): STOP LIGHT SWITCH: REMOVAL+

9. REMOVE BRAKE PEDAL RETURN SPRING

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 10/2019]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/ Vacuum Brake Booster): REMOVAL+

10. SEPARATE WIRE HARNESS

(a) Disconnect the connector.

(b) Disengage the 2 clamps to separate the wire harness from the brake pedal support assembly.

11. LOOSEN LOCK NUT

(a) Loosen the lock nut of the brake master cylinder push rod clevis.

*1

Lock Nut

*2

Brake Master Cylinder Push Rod Clevis

12. REMOVE PUSH ROD PIN

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 10/2019]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/ Vacuum Brake Booster): REMOVAL+

13. DISCONNECT CHECK VALVE TO CONNECTOR TUBE HOSE

(a) Slide the clip and disconnect the check valve to connector tube hose from the brake booster assembly.

14. REMOVE BRAKE BOOSTER ASSEMBLY

(a) Remove the bolt and nut.

(b) Disengage the guide and separate the wire harness.

(c) Apply protective tape to the vehicle body as shown in the illustration.

Protective Tape

(d) Disconnect the connector from the vacuum warning switch assembly.

(e) w/ Stop and Start System:

(1) Disconnect the connector from the vacuum sensor assembly.

(f) Disengage the 5 clamps to separate the brake tube clamp from the brake lines.

(g) Disengage the 5 clamps to remove the brake tube clamp from the brake lines.

(h) Disengage the 5 clamps to remove the brake tube clamp from the brake lines.

(i) Disengage the 3 clamps to separate the brake tube clamp from the brake lines.

(j) Remove the bolt and clamp to remove the 2 brake tube clamps from the vehicle body.

(k) Using a union nut wrench, remove the 2 brake lines from the brake actuator assembly.

NOTICE:

  • 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.

*a

From 1st Chamber of Brake Master Cylinder Sub-assembly

*b

From 2nd Chamber of Brake Master Cylinder Sub-assembly

(l) Remove the 4 nuts.

NOTICE:

Do not apply excessive force to the brake lines.

(m) Remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.

(n) Remove the brake booster assembly from the vehicle body.

NOTICE:

Do not apply excessive force to the brake lines.

15. REMOVE BRAKE BOOSTER GASKET

(a) Remove the brake booster gasket from the brake booster assembly.