Toyota RAV4 Quiz
Brake

Brake booster

In this manual: Brake
Introduction — 37Interior — 12Exterior — 432Az-fe engine mechanical — 1552Az-fe ignition — 182Az-fe charging — 232Az-fe emission control — 82az-fe exhaust — 32Az-fe fuel — 72Az-fe lubrication — 4Brake — 17Brake control — 63U140f automatic transaxle — 59Instrument panel — 8Suspension — 18Drive shaft — 23Axle — 6Tire and wheel — 30Air conditioning — 93Lighting — 45Cruise control — 21Differential — 12Door lock — 31Engine immobiliser — 21Horn — 5Can communication — 27Mirror — 5Parking brake — 5Power steering — 27Propeller shaft — 3Seat — 29Seat belt — 27Sliding roof — 25Steering column — 6Wiper and washer — 11Supplemental restraint system — 95Other system — 5Maintenance — 14
64steps
~384min
4/5difficulty
Done 0 of 64
Installation (2005/11-2006/01)
  1. Install check valve grommet
  2. Install the grommet to the booster.
  3. Install brake vacuum check valve assembly
  4. Install the check valve to the grommet.
  5. Install brake booster gasket
  6. Install a new gasket to the booster.
  7. Install brake master cylinder push rod clevis
  8. Install the push rod clevis to the booster.
  9. 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.

  1. Install brake booster assembly
  2. Install the booster with the 4 nuts.
  3. Install push rod pin
    Toyota RAV4. Install push rod pin
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*Lbf)
Toyota RAV4. Install push rod pin

  1. Apply lithium soap base glycol grease to the push rod pin.
  2. Install the push rod pin to the push rod clevis.
Notice:

The push rod pin must be installed as shown in the illustration.

  1. Install the clip to the push rod pin.
Notice:

The clip must be installed as shown in the illustration.

  1. Check and adjust brake booster push rod (see page br-24)
  2. Connect vacuum hose
  3. Connect the vacuum hose to the check valve.
  4. Install brake master cylinder subassembly (see page br-25)
  5. Install abs and traction actuator assembly with bracket (see page bc-186)
  6. Connect brake lines (see page bc-187)
  7. Fill reservoir with brake fluid (see page br- 6)
  8. Bleed air from brake master cylinder (see page br-7)
  9. Bleed air from brake line (see page br-7)
  10. Bleed air from abs and traction actuator assembly (see page br-8)
  11. Check and adjust brake pedal height (see page br-13)
  12. Check brake pedal free play (see page br- 14)
  13. Check brake pedal reserve distance (see page br-14)
  14. Check brake fluid level in reservoir (see page br-6)
  15. Check for brake fluid leakage
  16. Install air cleaner case sub-assembly
  17. 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- )
  1. Install check valve grommet
  2. Install the grommet to the booster.
  3. Install brake vacuum check valve assembly
  4. Install the check valve to the grommet.
  5. Install brake booster gasket
  6. Install a new gasket to the booster.
  7. Install brake master cylinder push rod clevis
  8. Install the push rod clevis to the booster.
  9. 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.

  1. Install brake booster assembly
  2. Install the booster with the 4 nuts.
  3. Install push rod pin
    Toyota RAV4. Install push rod pin
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*Lbf)
Toyota RAV4. Install push rod pin

  1. Apply lithium soap base glycol grease to the push rod pin.
  2. Install the push rod pin to the push rod clevis.
Notice:

The push rod pin must be installed as shown in the illustration.

  1. Install the clip to the push rod pin.
Notice:

The clip must be installed as shown in the illustration.

  1. Check and adjust brake booster push rod (see page br-24)
  2. Connect vacuum hose
  3. Connect the vacuum hose to the check valve.
  4. Install brake master cylinder subassembly (see page br-26)
  5. Install abs and traction actuator assembly with bracket (see page bc-187)
  6. Connect brake lines (see page bc-188)
  7. Fill reservoir with brake fluid (see page br- 6)
  8. Bleed air from brake master cylinder (see page br-7)
  9. Bleed air from brake line (see page br-7)
  10. Bleed air from abs and traction actuator assembly (see page br-8)
  11. Check and adjust brake pedal height (see page br-15)
  12. Check brake pedal free play (see page br- 15)
  13. Check brake pedal reserve distance (see page br-16)
  14. Check brake fluid level in reservoir (see page br-6)
  15. Check for brake fluid leakage
  16. Install air cleaner case sub-assembly (for 2az-fe)
  17. 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.

  1. Install air cleaner case (for 2gr-fe)
  2. 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.

Test yourself

A quick Toyota RAV4 quiz: every answer comes with an explanation and a link to the manual page.