Toyota RAV4 (XA40) 2013-2018 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.
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.
...
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:
Radiator
Components
On-vehicle inspection
Check radiator reservoir cap subassembly
Measure the valve opening pressure.
If there are water stains or foreign matter on oring
1, clean it with water and finger scouring.
Check that o-ring 1 is not deformed, cracked or
sw ...
Headlight relay
On-vehicle inspection
Remove headlight relay
Remove the headlight relay from the engine room
no. 2 Relay block.
Measure the resistance of the relay.
Standard resistance
If result is not as specified, replace the relay. ...
Power mirror control system
Parts location
System diagram
System description
The outer mirror switch controls the outer rear view mirror lh
and rh.
Problem symptoms table
Hint:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of pr ...