BRAKE SYSTEM (OTHER): BRAKE BOOSTER PUMP (w/o Vacuum Brake Booster): REMOVAL; 2020 MY RAV4 RAV4 HV [10/2019

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001LTXZ
Model Year Start: 2020	Model: RAV4	Prod Date Range: [10/2019 - 08/2020]
Title: BRAKE SYSTEM (OTHER): BRAKE BOOSTER PUMP (w/o Vacuum Brake Booster): REMOVAL; 2020 MY RAV4 RAV4 HV [10/2019 - 08/2020]

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 with master cylinder assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced (for HV Model)

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for HV model)*
		Pre-collision system
		Lighting system (EXT)(w/ AFS)
	Memorize steering angle neutral point	Parking assist monitor system
	Memorize steering angle neutral point	Panoramic view monitor system (for HV model)
	Reset back door close position	Power back door system (for HV model)
	Back door lock initialization	Power door lock control system

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 (-) auxiliary battery terminal.
While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

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

System Name	See Procedure
Vehicle enrolled in Toyota Audio Multimedia system or safety connect system	6 minutes
Vehicle not enrolled in Toyota Audio Multimedia 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
w/o Occupant Classification System:
Click here

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

2. DISABLE BRAKE CONTROL

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

4. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY

Click here

5. DRAIN BRAKE FLUID

NOTICE:

If brake fluid leaks onto any painted surface, immediately wash it off.

6. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE

(a) Slide the clip and disconnect the No. 2 brake actuator hose from the No. 1 brake actuator tube.

7. DISCONNECT ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE

(a) Using a union nut wrench, disconnect the accumulator to brake master cylinder tube from the brake booster pump assembly.

NOTICE:

Do not kink or damage the accumulator to brake master cylinder tube.
Do not allow any foreign matter such as dirt or dust to enter the accumulator to brake master cylinder tube from the connecting parts.

8. REMOVE BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET

(a) Release the lock lever and disconnect the connector from the brake booster pump assembly as shown in the illustration.

	Release the lock lever
	Disconnect the connector

NOTICE:

Be careful not to allow any brake fluid to enter the connector.

(b) Remove the nut, 2 bolts and brake booster pump assembly with bracket from the vehicle body.

NOTICE:

Do not apply excessive force to the brake lines.
Do not carry the brake booster pump assembly by the parts shown in the illustration.
Do not drop the brake booster pump assembly when carrying it.
Do not a brake booster pump assembly that has been dropped.
Be careful not to allow brake fluid to enter the connector.

*a	Union
*b	Connector
*c	Wire Harness
*d	Stud

9. REMOVE NO. 2 BRAKE ACTUATOR HOSE

(a) Slide the clip and remove the No. 2 brake actuator hose from the brake booster pump assembly.

10. REMOVE BRAKE BOOSTER PUMP ASSEMBLY

(a) Disengage the 2 clamps to separate the wire harness from the brake actuator bracket assembly.

(b) Remove the nut to separate the brake booster pump from the brake actuator bracket assembly.

*1	Brake Booster Pump
*2	Brake Actuator Bracket Assembly
*3	Brake Booster Pump Bushing
*4	No. 2 Brake Actuator Case Collar

(d) Remove the brake booster pump bushing and No. 2 brake actuator case collar from the brake actuator bracket assembly.

(e) Remove the 2 brake booster pump collars and 2 brake booster pump bushings from the brake booster pump assembly.

HINT:

Perform this procedure only when replacement of the brake booster pump collars or brake booster pump bushings is necessary.