TOYOTA RAV4 2006 Service Repair Manual

BR–16BRAKE – BRAKE PEDAL
BR
(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.
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.
C 111 3 0 2 E 0 1
C 111 3 0 6 E 0 1
C 111 3 3 9 E 0 1Engine Specified Condition
2AZ-FE (w/o 3rd seat) More than 95 mm (3.74 in.)
2AZ-FE (w/ 3rd seat) More than 120 mm (4.72 in.)
2GR-FE More than 120 mm (4.72 in.)

BRAKE – BRAKE PEDALBR–17
BR
REASSEMBLY
1. INSTALL BRAKE PEDAL PAD
(a) Install the pad to the pedal.
2. INSTALL STOP LIGHT SWITCH MOUNTING
ADJUSTER
(a) Install a new adjuster to the support.
INSTALLATION
1. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY
(a) Install the support with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)
(b) Install the bolt to the support.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
2. INSTALL PUSH ROD PIN
(a) Apply lithium soap base glycol grease to the push
rod pin.
C126454
C129086E01
C130666E04

BR–18BRAKE – BRAKE PEDAL
BR
(b) Install the push rod pin to the push rod clevis.
NOTICE:
The push rod pin must be installed as shown in
the illustration.
(c) Install the clip to the push rod pin.
NOTICE:
The clip must be installed as shown in the
illustration.
3. INSTALL STOP LIGHT SWITCH ASSEMBLY
(a) Insert the switch into the adjuster until the switch
body touches the pedal.
NOTICE:
Do not depress the pedal.
(b) 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.
(c) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
4. CONNECT CONNECTORS
(a) w/
296 disc brake:
Connect the brake pedal load sensing switch
connector.
(b) Connect the stop light switch connector.
5. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See
page BR-13)
6. CHECK BRAKE PEDAL FREE PLAY (See page BR-
14)
7. CHECK BRAKE PEDAL RESERVE DISTANCE (See
page BR-14)
8. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) Install the instrument panel (see page IP-9).
9. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
C 111 3 0 1 E 0 3
C 111 3 0 2 E 0 1

BRAKE – BRAKE MASTER CYLINDERBR–21
BR
ON-VEHICLE INSPECTION
1. CHECK BRAKE FLUID LEVEL WARNING SWITCH
(a) Remove the reservoir filler cap and strainer.
(b) Disconnect the brake fluid level warning switch
connector.
(c) Measure the resistance of the switch.
HINT:
There is a float inside the reservoir. Its position can
be changed by increasing or decreasing the brake
fluid level.
Standard resistance
If the value is not as specified, replace the brake
master cylinder reservoir sub-assembly.
(d) Add brake fluid to the MAX level.
C129064
Tester Connection Condition Specified Condition
1 - 2 Float up (Switch OFF) 10 k
or higher
1 - 2 Float down (Switch ON) Below 1

BR–22BRAKE – BRAKE MASTER CYLINDER
BR
REMOVAL
(2005/11-2006/01)
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure that the tip of the master cylinder points
downward when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
(a) Remove the air cleaner case (see page EM-98).
HINT:
Refer to the procedures from the removal of the
purge VSV up until the removal of the air cleaner
case.
2. DRAIN BRAKE FLUID
NOTICE:
Wash off brake fluid immediately if it comes in
contact with any painted surface.
3. REMOVE BRAKE MASTER CYLINDER SUB-
ASSEMBLY
(a) Release the vacuum pressure in the brake booster
as follows.
(1) Stop the engine.
(2) Depress the brake pedal several times.
(b) Disconnect the brake fluid level warning switch
connector labeled A.
(c) Using SST, disconnect the 2 brake lines labeled B
from the master cylinder.
SST 09023-00101
(d) Remove the 2 nuts.
(e) Pull out the master cylinder from the brake booster.
NOTICE:
• The master cylinder and piston are designed
so that the piston can easily fall out. Prevent
this by making sure that the tip of the master
cylinder points downward when handling the
master cylinder.
C127053E01
C127054

BRAKE – BRAKE MASTER CYLINDERBR–23
BR
• Make sure foreign matter does not attach to
the master cylinder's piston. If foreign matter
attaches, clean it off with a cloth. Then apply
lithium soap base glycol grease to the entire
outer circumference contact surface area of
the piston.
(f) Remove the O-ring from the master cylinder.

BR–24BRAKE – BRAKE MASTER CYLINDER
BR
REMOVAL
(2006/01- )
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure that the tip of the master cylinder points
downward when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for
2AZ-FE)
(a) Remove the air cleaner case (see page EM-98).
HINT:
Refer to the procedures from the removal of the
purge VSV up until the removal of the air cleaner
case.
2. REMOVE AIR CLEANER CASE (for 2GR-FE)
(a) Remove the air cleaner case (see page EM-21).
HINT:
Refer to the procedures from the removal of the air
cleaner cap sub-assembly up until the removal of
the air cleaner case.
3. DRAIN BRAKE FLUID
NOTICE:
Wash off brake fluid immediately if it comes in
contact with any painted surface.
4. REMOVE BRAKE MASTER CYLINDER SUB-
ASSEMBLY
(a) Release the vacuum pressure in the brake booster
as follows.
(1) Stop the engine.
(2) Depress the brake pedal several times.
(b) Disconnect the brake fluid level warning switch
connector labeled A.
(c) Using SST, disconnect the 2 brake lines labeled B
from the master cylinder.
SST 09023-00101
C127053E01

BRAKE – BRAKE MASTER CYLINDERBR–25
BR
(d) Remove the 2 nuts.
(e) Pull out the master cylinder from the brake booster.
NOTICE:
• The master cylinder and piston are designed
so that the piston can easily fall out. Prevent
this by making sure that the tip of the master
cylinder points downward when handling the
master cylinder.
• Make sure foreign matter does not attach to
the master cylinder's piston. If foreign matter
attaches, clean it off with a cloth. Then apply
lithium soap base glycol grease to the entire
outer circumference contact surface area of
the piston.
(f) Remove the O-ring from the master cylinder.
C127054

BR–26BRAKE – BRAKE MASTER CYLINDER
BR
DISASSEMBLY
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure to tip of the master cylinder points downward
when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. REMOVE BRAKE MASTER CYLINDER RING PIN
2. REMOVE BRAKE MASTER CYLINDER RESERVOIR
SUB-ASSEMBLY
3. REMOVE MASTER CYLINDER RESERVOIR
GROMMET
4. REMOVE BRAKE MASTER CYLINDER RESERVOIR
FILLER CAP ASSEMBLY
5. REMOVE BRAKE MASTER CYLINDER RESERVOIR
STRAINER

BRAKE – BRAKE MASTER CYLINDERBR–27
BR
INSPECTION
NOTICE:
• The master cylinder and piston are designed so that
the piston can easily fall out. Prevent this by making
sure that the tip of the master cylinder points
downward when handling the master cylinder.
• Make sure foreign matter does not attach to the
master cylinder's piston. If foreign matter attaches,
clean it off with a cloth. Then apply lithium soap base
glycol grease to the entire outer circumference
contact surface area of the piston.
1. INSPECT AND ADJUST BRAKE BOOSTER PUSH
ROD
HINT:
Adjust the booster push rod when the master cylinder is
replaced with a new one. Adjustment is not necessary
when the master cylinder is reinstalled and the booster is
replaced with a new one.
(a) Set SST on the master cylinder and lower the rod of
SST until it just touches the piston.
SST 09737-00013
(b) Apply chalk to the flat tip of the SST rod. Turn SST
upside down and measure the clearance between
the brake booster push rod and SST.
Standard clearance:
-0.21 to 0 mm (-0.0083 to 0 in.)
If there is clearance between the SST main body
and the shell of the brake booster, the push rod is
protruding too far. If the chalk does not stick to the
tip of the brake booster push rod, the push rod
protrusion is insufficient.
(c) If the clearance is not within the standard, adjust the
length by holding the rod using SST and turning the
tip of the rod using a 7 mm socket driver.
SST 09737-00020
NOTICE:
Check the push rod clearance again after
adjusting.
G028332E02
C128539E01