Abs And Traction Actuator (W/ Vsc) Installation

Brake. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
Brake Control. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. INSTALL BRAKE ACTUATOR WITH BRACKET

  2. CONNECT BRAKE LINES

  3. CONNECT CONNECTOR

  4. FILL RESERVOIR WITH BRAKE FLUID

  5. BLEED AIR FROM BRAKE MASTER CYLINDER

  6. BLEED AIR FROM BRAKE LINE

  7. BLEED AIR FROM BRAKE ACTUATOR ASSEMBLY

  8. BLEED AIR FROM CLUTCH LINE (for Manual Transaxle)

  9. CHECK BRAKE FLUID LEVEL IN RESERVOIR

  10. CHECK FOR BRAKE FLUID LEAK

  11. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1AZ-FE)

  12. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2AZ-FE)

  13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2GR-FE)

  14. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 3ZR-FAE)

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  16. CHECK BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER

Abs And Traction Actuator (W/ Vsc) -- Installation



1. INSTALL BRAKE ACTUATOR WITH BRACKET
NOTICE:
When installing a new brake actuator, do not remove the hole plug before connecting the brake tube. New actuators are filled with brake fluid.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Brake Control.Anti-Lock Brake System.Abs And Traction Actuator (W/ Vsc)  Installation
  1. Install the actuator with bracket with the 3 nuts.

    Torque:
    19 N*m{194 kgf*cm, 14 ft.*lbf}
    NOTICE:
    1. Tighten the 3 nuts uniformly in alphabetical order.
    2. Be careful not to damage the brake tubes.
    3. Do not drop the actuator. If dropped, replace it.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
  1. Connect the brake tube clamp to the bracket.



2. CONNECT BRAKE LINES


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Brake Control.Anti-Lock Brake System.Abs And Traction Actuator (W/ Vsc)  Installation
  1. Set each brake line in the correct position on the brake actuator as shown in the illustration.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Brake Control.Anti-Lock Brake System.Abs And Traction Actuator (W/ Vsc)  Installation
  1. Using a union nut wrench, connect the 6 brake lines to the correct locations on the actuator, as shown in the illustration.

    Torque:
    without union nut wrench:
    15 N*m{155 kgf*cm, 11 ft.*lbf}
    with union nut wrench:
    14 N*m{145 kgf*cm, 10 ft.*lbf}
    HINT:
    1. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
    2. This torque value is effective when the union nut wrench is parallel to the torque wrench.


3. CONNECT CONNECTOR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
  1. Connect the connector and push the lock lever downward.



4. FILL RESERVOIR WITH BRAKE FLUID
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
NOTICE:
  1. Make sure there is sufficient brake fluid in the can.
  2. After adding braking fluid, make sure the reservoir is sufficiently full.


5. BLEED AIR FROM BRAKE MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
  1. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

  1. Slowly depress and hold the brake pedal.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
  1. Block the outer holes with your fingers, and release the pedal.

  1. Repeat the 2 previous steps 3 or 4 times.

  1. Using a union nut wrench, connect the 2 brake lines to the master cylinder.

    Torque:
    without union nut wrench:
    15.2 N*m{155 kgf*cm, 11 ft.*lbf}
    with union nut wrench:
    14 N*m{144 kgf*cm, 10 ft.*lbf}
    HINT:
    1. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
    2. This torque value is effective when the union nut wrench is parallel to the torque wrench.


6. BLEED AIR FROM BRAKE LINE



Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Brake Control.Anti-Lock Brake System.Abs And Traction Actuator (W/ Vsc)  Installation

  1. Remove the bleeder plug cap.

  1. Connect the vinyl tube to the bleeder plugs.

  1. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

  1. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

  1. Repeat the 2 previous steps until all the air in the brake fluid is gone.

  1. Tighten the bleeder plug.

    Torque:
    8.3 N*m{85 kgf*cm, 73 in.*lbf}
  1. Install the cap.

  1. Bleed air from the brake line for each wheel by repeating the above procedures.



7. BLEED AIR FROM BRAKE ACTUATOR ASSEMBLY
NOTICE:
After bleeding the air from the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding of the brake actuator with an intelligent tester by following the procedure below.
  1. Depress the brake pedal more than 20 times with the engine off.

  1. Connect the intelligent tester to the DLC3, and turn the ignition switch on (IG).

    NOTICE:
    Do not start the engine.
  1. Select AIR BLEEDING on the intelligent tester.

    HINT:
    Refer to the intelligent tester operator's manual for further details.
  1. Bleed the air out of the suction line.

    NOTICE:
    1. Perform the bleeding at the right front wheel and right rear wheel.
    2. Bleed the air by following the steps displayed on the intelligent tester.

    1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel.

    2. Loosen the bleeder plug.

    3. Operate the brake actuator to bleed the air using the intelligent tester.

      NOTICE:
      Release the brake pedal at this time.
      HINT:
      This operation stops automatically after 4 seconds.
    4. Check if the operation has stopped by referring to the intelligent tester display.

    5. Temporarily tighten the bleeder plug.

    6. Repeat the 4 previous steps until all air in the fluid is completely bled out.

    7. Tighten the bleeder plug.

      Torque:
      8.3 N*m{85 kgf*cm, 73 in.*lbf}
    8. Repeat all of the above procedures for the right rear wheel to bleed the air out of the suction line.

  1. Bleed the air out of the pressure reduction line.

    NOTICE:
    1. Perform the bleeding at the 4 wheels.
    2. Bleed the air by following the steps displayed on the intelligent tester.

    1. Connect a vinyl tube to either one of the bleeder plugs.

    2. Loosen the bleeder plug.

    3. Using the intelligent tester, operate the brake actuator assembly, completely depress the brake pedal and hold it there.

      NOTICE:
      1. During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid comes out of the bleeder plug.
      2. Hold the brake pedal depressed. Do not depress and release the pedal repeatedly.
      HINT:
      The operation stops automatically after 4 seconds. When performing this procedure continuously, set an interval of at least 20 seconds.
    4. Tighten the bleeder plug, then release the brake pedal.

    5. Repeat the 3 previous steps until all air in the fluid is completely bled out.

    6. Tighten the bleeder plug.

      Torque:
      8.3 N*m{85 kgf*cm, 73 in.*lbf}
    7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure reduction line.



8. BLEED AIR FROM CLUTCH LINE (for Manual Transaxle)
  1. Fill the brake reservoir with brake fluid and bleed the clutch system.

    Torque:
    8.3 N*m{85 kgf*cm, 73 in.*lbf}


9. CHECK BRAKE FLUID LEVEL IN RESERVOIR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
  1. Check the fluid level and add fluid if necessary.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT3
    HINT:
    Add fluid to a level between the reservoir's MIN and MAX lines.


10. CHECK FOR BRAKE FLUID LEAK


11. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1AZ-FE)
  1. Install the air cleaner case (RAV4_ACA30 RM000001BC100NX.html).



12. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2AZ-FE)
  1. Install the air cleaner case (RAV4_ACA30 RM000001BC100OX.html).



13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2GR-FE)
  1. Install the air cleaner case (RAV4_ACA30 RM0000019Y7015X.html).



14. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 3ZR-FAE)
  1. Install the air cleaner case (RAV4_ACA30 RM000003PXK003X.html).



15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


16. CHECK BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER
  1. Check the brake actuator with the intelligent tester (RAV4_ACA30 RM000001XV501CX.html).