TOYOTA RAV4 2006 Service Repair Manual

BR–28BRAKE – BRAKE MASTER CYLINDER
BR
REASSEMBLY
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. INSTALL BRAKE MASTER CYLINDER RESERVOIR
STRAINER
2. INSTALL BRAKE MASTER CYLINDER RESERVOIR
FILLER CAP ASSEMBLY
3. INSTALL MASTER CYLINDER RESERVOIR
GROMMET
(a) Apply lithium soap base glycol grease to 2 new
grommets, and then install them to the master
cylinder.
4. INSTALL BRAKE MASTER CYLINDER RESERVOIR
SUB-ASSEMBLY
5. INSTALL BRAKE MASTER CYLINDER RING PIN
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BRAKE – BRAKE MASTER CYLINDERBR–29
BR
INSTALLATION
(2005/11-2006/01)
1. INSTALL BRAKE MASTER CYLINDER SUB-
ASSEMBLY
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.
(a) Install a new O-ring to the master cylinder.
(b) Install the master cylinder to the booster with the 2
nuts.
Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf)
(c) Using SST, connect the 2 brake lines labeled B to
the master cylinder.
SST 09023-00101
Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) without
SST
14 N*m (144 kgf*cm, 10 ft.*lbf) with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
(d) Connect the brake fluid level warning switch
connector labeled A to the master cylinder.
2. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
6)
3. BLEED AIR FROM BRAKE MASTER CYLINDER (See
page BR-7)
4. BLEED AIR FROM BRAKE LINE (See page BR-7)
5. BLEED AIR FROM ABS AND TRACTION ACTUATOR
ASSEMBLY (See page BR-8)
6. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-6)
7. CHECK FOR BRAKE FLUID LEAKAGE
C127054
C127053E01

BR–30BRAKE – BRAKE MASTER CYLINDER
BR
8. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) 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.

BRAKE – BRAKE MASTER CYLINDERBR–31
BR
INSTALLATION
(2006/01- )
1. INSTALL BRAKE MASTER CYLINDER SUB-
ASSEMBLY
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.
(a) Install a new O-ring to the master cylinder.
(b) Install the master cylinder to the booster with the 2
nuts.
Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf)
(c) Using SST, connect the 2 brake lines labeled B to
the master cylinder.
SST 09023-00101
Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) without
SST
14 N*m (144 kgf*cm, 10 ft.*lbf) with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
(d) Connect the brake fluid level warning switch
connector labeled A to the master cylinder.
2. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
6)
3. BLEED AIR FROM BRAKE MASTER CYLINDER (See
page BR-7)
4. BLEED AIR FROM BRAKE LINE (See page BR-7)
5. BLEED AIR FROM ABS AND TRACTION ACTUATOR
ASSEMBLY (See page BR-8)
6. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-6)
7. CHECK FOR BRAKE FLUID LEAKAGE
C127054
C127053E01

BR–32BRAKE – BRAKE MASTER CYLINDER
BR
8. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for
2AZ-FE)
(a) 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.
9. INSTALL AIR CLEANER CASE (for 2GR-FE)
(a) 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.

BRAKE – BRAKE BOOSTERBR–31
BR
REMOVAL
(2005/11-2006/01)
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. DISCONNECT BRAKE LINES (See page BC-181)
4. REMOVE ABS AND TRACTION ACTUATOR
ASSEMBLY WITH BRACKET (See page BC-182)
5. REMOVE BRAKE MASTER CYLINDER SUB-
ASSEMBLY (See page BR-21)
6. DISCONNECT VACUUM HOSE
7. REMOVE PUSH ROD PIN
(a) Remove the clip from the push rod pin.
(b) Remove the push rod pin from the push rod clevis.
8. REMOVE BRAKE MASTER CYLINDER PUSH ROD
CLEVIS
(a) Loosen the push rod clevis lock nut.
(b) Remove the push rod clevis.
9. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the 4 nuts.
(b) Pull out the booster with gasket.
10. REMOVE BRAKE BOOSTER GASKET
11. REMOVE BRAKE VACUUM CHECK VALVE
ASSEMBLY
12. REMOVE CHECK VALVE GROMMET
C126454

BR–32BRAKE – BRAKE BOOSTER
BR
REMOVAL
(2006/01- )
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. DISCONNECT BRAKE LINES (See page BC-183)
5. REMOVE ABS AND TRACTION ACTUATOR
ASSEMBLY WITH BRACKET (See page BC-184)
6. REMOVE BRAKE MASTER CYLINDER SUB-
ASSEMBLY (See page BR-22)
7. DISCONNECT VACUUM HOSE
8. REMOVE PUSH ROD PIN
(a) Remove the clip from the push rod pin.
(b) Remove the push rod pin from the push rod clevis.
9. REMOVE BRAKE MASTER CYLINDER PUSH ROD
CLEVIS
(a) Loosen the push rod clevis lock nut.
(b) Remove the push rod clevis.
10. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the 4 nuts.
(b) Pull out the booster with gasket.
11. REMOVE BRAKE BOOSTER GASKET
12. REMOVE BRAKE VACUUM CHECK VALVE
ASSEMBLY
13. REMOVE CHECK VALVE GROMMET
C126454

BRAKE – BRAKE BOOSTERBR–33
BR
INSTALLATION
(2005/11-2006/01)
1. INSTALL CHECK VALVE GROMMET
(a) Install the grommet to the booster.
2. INSTALL BRAKE VACUUM CHECK VALVE
ASSEMBLY
(a) Install the check valve to the grommet.
3. INSTALL BRAKE BOOSTER GASKET
(a) Install a new gasket to the booster.
4. INSTALL BRAKE MASTER CYLINDER PUSH ROD
CLEVIS
(a) Install the push rod clevis to the booster.
(b) 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.
5. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Install the booster with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)
6. INSTALL PUSH ROD PIN
(a) Apply lithium soap base glycol grease to the push
rod pin.
(b) Install the push rod pin to the push rod clevis.
NOTICE:
The push rod pin must be installed as shown in
the illustration.
C126454
C130666E04

BR–34BRAKE – BRAKE BOOSTER
BR
(c) Install the clip to the push rod pin.
NOTICE:
The clip must be installed as shown in the
illustration.
7. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD
(See page BR-24)
8. CONNECT VACUUM HOSE
(a) Connect the vacuum hose to the check valve.
9. INSTALL BRAKE MASTER CYLINDER SUB-
ASSEMBLY (See page BR-25)
10. INSTALL ABS AND TRACTION ACTUATOR
ASSEMBLY WITH BRACKET (See page BC-186)
11. CONNECT BRAKE LINES (See page BC-187)
12. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
6)
13. BLEED AIR FROM BRAKE MASTER CYLINDER (See
page BR-7)
14. BLEED AIR FROM BRAKE LINE (See page BR-7)
15. BLEED AIR FROM ABS AND TRACTION ACTUATOR
ASSEMBLY (See page BR-8)
16. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See
page BR-13)
17. CHECK BRAKE PEDAL FREE PLAY (See page BR-
14)
18. CHECK BRAKE PEDAL RESERVE DISTANCE (See
page BR-14)
19. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-6)
20. CHECK FOR BRAKE FLUID LEAKAGE
21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) 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.

PB–10PARKING BRAKE – PARKING BRAKE CABLE
PB
INSTALLATION
1. INSTALL PARKING BRAKE CABLE
(a) Connect the cable to the backing plate and parking
brake shoe lever.
(1) Pass the cable through the backing plate, and
then connect the cable to the lever.
(2) Install the cable to the backing plate with the
bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(b) Install the clamp and clamp bolt (labeled F) to the
trailing arm.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
(c) Install the clamp and clamp bolt (labeled E) to the
rear suspension crossmember.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
NOTICE:
Securely install the clamp.
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