TOYOTA RAV4 2006 Service Repair Manual

BC–58BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
FR ABS STATUS FR wheel ABS control status / ON
or OFFON: During control -
FL ABS STATUS FL wheel ABS control status / ON
or OFFON: During control -
RR ABS STATUS RR wheel ABS control status / ON
or OFFON: During control -
RL ABS STATUS RL wheel ABS control status / ON
or OFFON: During control -
RR EBD STATUS RR wheel EBD control status /
ON or OFFON: During control -
RL EBD STATUS RL wheel EBD control status / ON
or OFFON: During control -
BA STATUS BA control status / ON or OFF ON: During control -
TRAC STATUS TRC control status / ON or OFF ON: During control -
TRAC ENG STATUS TRC engine control status / ON or
OFFON: During control -
TRAC BRK STATUS TRC brake control status / ON or
OFFON: During control -
FR VSC STATUS FR wheel VSC control status / ON
or OFFON: During control -
FL VSC STATUS FL wheel VSC control status / ON
or OFFON: During control -
RR VSC STATUS RR wheel VSC control status /
ON or OFFON: During control -
RL VSC STATUS RL wheel VSC control status / ON
or OFFON: During control -
ENG REVOLUTIONS Engine revolutions / min.: 0 r/min,
max.: 65535 r/min--
ENGINE TORQUE Real engine torque / min.: -1024
Nm, max.: 1023 Nm--
ACCELERATOR % Percentage of accelerator pedal
opening angle / min.: 0%, max.:
128%--
SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON
OFF: Solenoid relay OFF-
ELECTRONICALLY
CONTROLLED BRAKE SYSTEM
MTR RELAYElectronically Controlled Brake
System Motor relay (VSC1 relay)
/ ON or OFFON: Motor relay ON
OFF: Motor relay OFF-
FAIL MTR RELAY Fail-safe motor relay / ON or OFF ON: Motor relay ON
OFF: Motor relay OFF-
SM2 TRC / VSC solenoid (SM2) / ON
or OFFON: Operates -
SM1 TRC / VSC solenoid (SM1) / ON
or OFFON: Operates -
SFRH*1 ABS solenoid (SFRH) / ON or
OFFON: Operates
OFF: Does not operate-
SFRR*2 ABS solenoid (SFRR) / ON or
OFFON: Operates
OFF: Does not operate-
SFLH*3 ABS solenoid (SFLH) / ON or
OFFON: Operates
OFF: Does not operate-
SFLR*4 ABS solenoid (SFLR) / ON or
OFFON: Operates
OFF: Does not operate-
SRRH*5 ABS solenoid (SRRH) / ON or
OFFON: Operates
OFF: Does not operate-
SRRR*6 ABS solenoid (SRRR) / ON or
OFFON: Operates
OFF: Does not operate-
SRLH*7 ABS solenoid (SRLH) / ON or
OFFON: Operates
OFF: Does not operate- Tester Display Measurement Item/Range Normal Condition Diagnostic Note

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–59
BC
HINT:
• *1: SFRH (S: Solenoid, F: Front, R: Right, H:
Holding)
• *2: SFRR (S: Solenoid, F: Front, R: Right, R:
Reduction)
• *3: SFLH (S: Solenoid, F: Front, L: Left, H:
Holding)
• *4: SFLR (S: Solenoid, F: Front, L: Left, R:
Reduction)
• *5: SRRH (S: Solenoid, R: Rear, R: Right, H:
Holding)
• *6: SRRR (S: Solenoid, R: Rear, R: Right, R:
Reduction)
• *7: SRLH (S: Solenoid, R: Rear, L: Left, H:
Holding)
• *8: SRLR (S: Solenoid, R: Rear, L: Left, R:
Reduction)
• *9: w/ Downhill assist control
• *10: for 2WD (w/ AUTO LSD)
SRLR*8 ABS solenoid (SRLR) / ON or
OFFON: Operates
OFF: Does not operate-
FR SPD OPN FR speed sensor open detection /
ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
FL SPD OPN FL speed sensor open detection /
ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
RR SPD OPN RR speed sensor open detection /
ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
RL SPD OPN RL speed sensor open detection /
ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
EFI COM OPN EFI communication open
detection / ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
YAW RATE OPN Yaw rate sensor open detection /
ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
DECELERAT OPN Deceleration sensor open
detection / ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
STEERING OPN Steering angle sensor open
detection / ERROR or NORMALERROR: Momentary interruption
NORMAL: Normal-
M/C OPN Master cylinder pressure sensor
open detection / ERROR or
NORMALERROR: Momentary interruption
NORMAL: Normal-
#DTC Number of recorded DTCs/ min.:
0, max.: 255Min.: 0
Max.: 255-
INSPECTION MODE Inspection mode / OTHER or
INSPECT--
#IG ON2 Number of ignition switch ON
operations after entering the
inspection mode / min.: 0, max.:
255-- Tester Display Measurement Item/Range Normal Condition Diagnostic Note

BC–60BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
2. PARFORM ACTIVE TEST
HINT:
Performing the intelligent tester's ACTIVE TEST allows
relay, VSV, actuator and other items to be operated
without removing any parts. Performing the ACTIVE
TEST early in troubleshooting is one way to save time.
The DATA LIST can be displayed during the ACTIVE
TEST.
(a) Connect the intelligent tester (with CAN VIM) to the
DLC3.
(b) Turn the ignition switch ON.
(c) Turn the intelligent tester on.
(d) Perform the ACTIVE TEST according to the display
on the tester.
HINT:
• The ignition switch must be turned ON to
proceed to the ACTIVE TEST using the
intelligent tester.
• The ACTIVE TESTs of the ABS solenoid, ABS
motor relay, ABS warning light and BRAKE
warning light are available when the vehicle is
stopped.
• The motors stop automatically after 5 seconds of
activation to prevent them from being damaged.
When the motors are driven repeatedly, certain
intervals are required.
• Each solenoid stops automatically after 2
seconds of activation to prevent them from being
damaged, and can be operated again after a
certain interval.
• Do not depress the brake pedal while only the
pressure reduction solenoid valves are on.
• Do not drive 2 or more solenoids simultaneously
except to operate the pressure holding solenoid
valves and pressure reduction solenoid valves of
each wheel.
Skid control ECU
Tester Display Test Part Control Range
ABS WARN LAMP Turns ABS warning light ON / OFF Observe combination meter
VSC WARN LAMP Turns VSC warning light ON / OFF Observe combination meter
BRAKE WARN LAMP Turns Brake warning light ON / OFF Observe combination meter
SLIP INDI LAMP Turns Slip indicator light ON / OFF Observe combination meter
D-HILL LIGHT*1 Turns downhill assist control indicator light ON /
OFFObserve combination meter
AUTO LSD LAMP*2 Turns AUTO LSD indicator light ON / OFF Observe combination meter
BUZZER Turns skid control buzzer ON / OFF Buzzer can be heard
STP LAMP RELAY Turns stop light relay (BRK relay) ON / OFF Operation sound of motor can be heard
SOL RELAY Turns ABS solenoid relay ON / OFF -
MOTOR RELAY Turns ABS motor relay ON / OFF Operation sound of motor can be heard
SRLR Turns ABS solenoid (SRLR) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SRLH Turns ABS solenoid (SRLH) ON / OFF Operation sound of solenoid (clicking sound)
can be heard

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–61
BC
HINT:
*1: w/ Downhill assist control
*2: for 2WD (w/ AUTO LSD)
SRRR Turns ABS solenoid (SRRR) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SRRH Turns ABS solenoid (SRRH) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SFLR Turns ABS solenoid (SFLR) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SFLH Turns ABS solenoid (SFLH) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SFRR Turns ABS solenoid (SFRR) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SFRH Turns ABS solenoid (SFRH) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SMR Turns VSC / TRC solenoid (SMR) ON / OFF Operation sound of solenoid (clicking sound)
can be heard
SMF Turns VSC / TRC solenoid (SMF (BA-SOL)) ON
/ OFFOperation sound of solenoid (clicking sound)
can be heard Tester Display Test Part Control Range

BRAKE – BRAKE SYSTEMBR–5
BR
PROBLEM SYMPTOMS TABLE
(2006/01- )
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 probability in the "Suspected Area" column
of the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
Brake system
Symptom Suspected Area See page
Low pedal or spongy pedal1. Fluid leaks in brake system -
2. Air in brake systemBR-6
3. Front brake piston seals (worn or damaged)BR-40
4. Rear brake piston seals (worn or damaged)BR-55
5. Brake master cylinder (faulty)BR-22
6. Booster push rod (adjustment necessary)BR-24
Brake drag1. Brake pedal free play (minimum)BR-15
2. Parking brake lever travel (adjustment necessary)PB-1
3. Parking brake cable (sticking)PB-8
4. Parking brake shoe clearance (adjustment necessary)PB-17
5. Front brake pad (cracked or distorted)BR-40
6. Rear brake pad (cracked or distorted)BR-55
7. Parking brake lining (cracked or distorted)PB-13
8. Front brake piston (stuck or frozen)BR-40
9. Rear brake piston (stuck or frozen)BR-55
10. Parking brake shoe return tension springPB-13
11. Booster push rod (adjustment necessary)BR-24
12. Vacuum leaks in booster systemBR-29
13. Brake master cylinder (faulty)BR-22
Brake pull1. Front brake piston (stuck or frozen)BR-40
2. Rear brake piston (stuck or frozen)BR-55
3. Front brake pad (oily, cracked or distorted)BR-40
4. Rear brake pad (oily, cracked or distorted)BR-55
5. Parking brake lining (oily, cracked or distorted)PB-13
6. Front brake disc (uneven wear)BR-40
7. Rear brake disc (uneven wear)BR-55
Hard pedal but braking inefficient1. Front brake pad (worn, cracked, distorted, oily or glazed)BR-40
2. Rear brake pad (worn, cracked, distorted, oily or glazed)BR-55
3. Parking brake lining (worn, cracked, distorted, oily or
glazed)PB-13
4. Front brake disc (uneven wear)BR-40
5. Rear brake disc (uneven wear)BR-55
6. Booster push rod (adjustment necessary)BR-24
7. Vacuum leaks in booster systemBR-29

BR–6BRAKE – BRAKE SYSTEM
BR
Noise from brakes1. Front brake pad (cracked, distorted, dirty or glazed)BR-40
2. Rear brake pad (cracked, distorted, dirty or glazed)BR-55
3. Front disc brake pad support plate (loose)BR-40
4. Rear disc brake pad support plate (loose)BR-55
5. Front disc brake cylinder slide pin (worn)BR-40
6. Rear disc brake cylinder slide pin (worn)BR-55
7. Front brake installation bolt (loose)BR-45
8. Rear brake installation bolt (loose)BR-60
9. Front brake disc (scored)BR-40
10. Rear brake disc (scored)BR-55
11. Parking brake shoe return tension spring (faulty)PB-13
12. Front brake anti-squeal shim (damaged)BR-40
13. Rear brake anti-squeal shim (damaged)BR-55
14. Parking brake shoe hold-down spring (damaged)PB-13 Symptom Suspected Area See page

BR–12BRAKE – BRAKE PEDAL
BR
REMOVAL
1. 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.
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) Remove the instrument panel (see page IP-4).
3. DISCONNECT CONNECTORS
(a) Disconnect the stop light switch connector.
(b) w/
296 disc brake:
Disconnect the brake pedal load sensing switch
connector.
4. REMOVE STOP LIGHT SWITCH ASSEMBLY
(a) Turn the switch counterclockwise and remove it.
5. REMOVE PUSH ROD PIN
(a) Remove the clip from the push rod pin.
(b) Remove the push rod pin from the push rod clevis.
6. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY
(a) Remove the bolt from the support.
(b) Remove the 4 nuts and support.
C129086E01
C126454

BRAKE – BRAKE PEDALBR–13
BR
DISASSEMBLY
1. REMOVE STOP LIGHT SWITCH MOUNTING
ADJUSTER
(a) Remove the adjuster from the support.
2. REMOVE BRAKE PEDAL PAD
(a) Remove the pad from the pedal.
INSPECTION
1. INSPECT STOP LIGHT SWITCH ASSEMBLY
(a) Measure the resistance of the switch.
Standard resistance
If the result is not as specified, replace the stop light
switch assembly.
ADJUSTMENT
(2005/11-2006/01)
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Check the pedal height.
Standard pedal height from dash panel:
184.2 to 194.2 mm (7.252 to 7.646 in.)
(b) Adjust the pedal height.
(1) Disconnect the connector from the stop light
switch.
(2) Remove the switch.
(3) Loosen the push rod clevis lock nut.
(4) Adjust the pedal height by turning the push rod.
(5) Tighten the lock nut.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
C118699E03
Tester Connection Switch Condition Specified Condition
1 - 2 Switch pin released Below 1
1 - 2 Switch pin pushed in 10 k or higher
C129085E01

BR–14BRAKE – BRAKE PEDAL
BR
(6) Insert the switch into the adjuster until the
switch body touches the pedal.
NOTICE:
Do not depress the pedal.
(7) 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.
(8) Connect the connector to the switch.
(9) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
2. CHECK BRAKE PEDAL FREE PLAY
(a) Stop the engine. Depress the pedal several times
until there is no vacuum in the booster. Then
release the pedal.
(b) Depress the pedal until resistance is felt.
(c) 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.
(d) 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.
C 111 3 0 1 E 0 3
C 111 3 0 2 E 0 1
C 111 3 0 6 E 0 1

BRAKE – BRAKE PEDALBR–15
BR
3. CHECK BRAKE PEDAL RESERVE DISTANCE
(a) Release the parking brake lever. Start the engine.
(b) Depress the pedal and check the pedal reserve
distance.
(1) Depress the pedal with a force of 490 N (50 kgf,
11 0 l b f ) .
(2) Measure the distance between the pedal and
dash panel shown in the illustration.
Standard pedal reserve distance
If the distance is not as specified, troubleshoot
the brake system.
ADJUSTMENT
(2006/01- )
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Check the pedal height.
Standard pedal height from dash panel:
184.2 to 194.2 mm (7.252 to 7.646 in.)
(b) Adjust the pedal height.
(1) Disconnect the connector from the stop light
switch.
(2) Remove the switch.
(3) Loosen the push rod clevis lock nut.
(4) Adjust the pedal height by turning the push rod.
(5) Tighten the lock nut.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
(6) Insert the switch into the adjuster until the
switch body touches the pedal.
NOTICE:
Do not depress the pedal.
C 111 3 3 9 E 0 1Engine Seat Type Specified Condition
2AZ-FE w/o 3rd seat More than 95 mm (3.74
in.)
w/ 3rd seat More than 120 mm (4.72
in.)
C129085E01
C 111 3 0 1 E 0 3