Toyota RAV4 (XA40) 2013-2018 Service Manual: Brake pedal
Components
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Removal
- Disconnect cable from negative battery
terminal
Caution:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
- Remove instrument panel sub-assembly
- Remove the instrument panel (see page ip-4).
- Disconnect connectors
- Disconnect the stop light switch connector.
- W/
296 disc brake:
disconnect the brake pedal load sensing switch
connector.
- Remove stop light switch assembly
- Turn the switch counterclockwise and remove it.
- Remove push rod pin
- Remove the clip from the push rod pin.
- Remove the push rod pin from the push rod clevis.
- Remove brake pedal support assembly
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- Remove the bolt from the support.
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- Remove the 4 nuts and support.
Disassembly
- Remove stop light switch mounting
adjuster
- Remove the adjuster from the support
- Remove brake pedal pad
Inspection
- Inspect stop light switch assembly
- Measure the resistance of the switch.
Standard resistance 
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If the result is not as specified, replace the stop light
switch assembly.
Adjustment (2005/11-2006/01)
- Check and adjust brake pedal height
- Check the pedal height.
Standard pedal height from dash panel:
184.2 To 194.2 Mm (7.252 To 7.646 In
.)
- Adjust the pedal height.
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- Disconnect the connector from the stop light
switch.
- Remove the switch.
- Loosen the push rod clevis lock nut.
- Adjust the pedal height by turning the push rod.
- Tighten the lock nut.
Torque: 26 n*m (265 kgf*cm, 19 ft.*Lbf)
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- Insert the switch into the adjuster until the
switch body touches the pedal.
Notice:
Do not depress the pedal.
- Turn the switch a quarter turn clockwise.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*Lbf) or
less
Notice:
Do not depress the pedal.
- Connect the connector to the switch.
- Check the switch clearance.
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Standard stop light switch clearance:
1.5 To 2.5 Mm (0.059 To 0.098 In.)
- Check brake pedal free play
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- Stop the engine. Depress the pedal several times
until there is no vacuum in the booster. Then
release the pedal.
- Depress the pedal until resistance is felt.
- Check the pedal's free play by measuring the
distance between the position in the previous step
and the pedal's released position.
Standard pedal free play:
1.0 To 6.0 Mm (0.039 To 0.236 In.)
If the free play is not as specified, check the switch
clearance in the next step.
If the free play is as specified, proceed to the
"check brake pedal reserve distance"
procedure.
- Check the switch clearance.
Standard stop light switch clearance:
1.5 To 2.5 Mm (0.059 To 0.098 In.)
If the clearance is not as specified, reinstall the
switch and recheck the pedal's free play.
If the clearance is as specified, troubleshoot the
brake system and proceed to the "check brake
pedal reserve distance" procedure.
- Check brake pedal reserve distance
- Release the parking brake lever. Start the engine.
- Depress the pedal and check the pedal reserve
distance.
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Standard pedal reserve distance 
If the distance is not as specified, troubleshoot
the brake system.
Adjustment
(2006/01- )
- Check and adjust brake pedal height
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- Check the pedal height.
Standard pedal height from dash panel:
184.2 To 194.2 Mm (7.252 To 7.646 In.)
- Adjust the pedal height.
- Disconnect the connector from the stop light
switch.
- Remove the switch.
- Loosen the push rod clevis lock nut.
- Adjust the pedal height by turning the push rod.
- Tighten the lock nut.
Torque: 26 n*m (265 kgf*cm, 19 ft.*Lbf)
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- Insert the switch into the adjuster until the
switch body touches the pedal.
Notice:
Do not depress the pedal.
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- Turn the switch a quarter turn clockwise.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*Lbf) or
less
Notice:
Do not depress the pedal.

- Connect the connector to the switch.
- Check the switch clearance.
Standard stop light switch clearance:
1.5 To 2.5 Mm (0.059 To 0.098 In.)
- Check brake pedal free play
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- Stop the engine. Depress the pedal several times
until there is no vacuum in the booster. Then
release the pedal.
- Depress the pedal until resistance is felt.
- Check the pedal's free play by measuring the
distance between the position in the previous step
and the pedal's released position.
Standard pedal free play:
1.0 To 6.0 Mm (0.039 To 0.236 In.)
If the free play is not as specified, check the switch
clearance in the next step.
If the free play is as specified, proceed to the
"check brake pedal reserve distance"
procedure.
- Check the switch clearance.
Standard stop light switch clearance:
1.5 To 2.5 Mm (0.059 To 0.098 In.)
If the clearance is not as specified, reinstall the
switch and recheck the pedal's free play.
If the clearance is as specified, troubleshoot the
brake system and proceed to the "check brake
pedal reserve distance" procedure.
- Check brake pedal reserve distance
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- Release the parking brake lever. Start the engine.
- Depress the pedal and check the pedal reserve
distance.
- Depress the pedal with a force of 490 n (50 kgf,
110 lbf).
- Measure the distance between the pedal and
dash panel shown in the illustration.
Standard pedal reserve distance
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If the distance is not as specified, troubleshoot
the brake system.
Reassembly
- Install brake pedal pad
- Install the pad to the pedal.
- Install stop light switch mounting
adjuster
- Install a new adjuster to the support.
Installation
- Install brake pedal support assembly
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- Install the support with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*Lbf)
- Install the bolt to the support.
Torque: 25 n*m (255 kgf*cm, 18 ft.*Lbf)
- Install push rod pin
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- 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.
- Install stop light switch assembly

- Insert the switch into the adjuster until the switch
body touches the pedal.
Notice:
Do not depress the pedal.
- Turn the switch a quarter turn clockwise.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*Lbf) or less
Notice:
Do not depress the pedal.
- Check the switch clearance.
Standard stop light switch clearance:
1.5 To 2.5 Mm (0.059 To 0.098 In.)
- Connect connectors
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- W/ ö296 disc brake:
Connect the brake pedal load sensing switch
connector.
- Connect the stop light switch connector.
- 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)
- Install instrument panel sub-assembly
- Install the instrument panel (see page ip-9).
- Connect cable to negative battery
terminal
Hint:
If any work is performed on the brake system or if air in the
brake lines is suspected, bleed air from the brake system.
Notice:
Wash off brake fluid immediately if it comes in contact
with ...
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.
...
Other materials:
Opening the back door from outside the vehicle
Back door opener
Vehicles without a power
back door
Raise the back door while
pressing up the back door
opener switch.
Vehicles with a power back
door
When the back door is
unlocked: press the back door
opener switch.
When the back door is locked
(vehicles with a smart key ...
System description
General
The air conditioning system has the following
features:
In accordance with the temperature set using the
temperature control switch, the air conditioning
amplifier determines the outlet temperature
based on the input signals from various sensors.
In addition, corre ...
Disassembly
Remove park/neutral position switch assembly
Remove the nut, washer and control shaft lever.
Using a screwdriver, pry off the lock plate.
Remove the nut and lock plate.
Remove the 2 bolts and pull out the switch.
Remove breather plug hose
Remove oil coo ...