This procedure replaces the ABS hydraulic control module on 2019-2024 Toyota RAV4 2.5L I4 FWD models. This is a safety-critical brake system component requiring brake fluid bleeding and system initialization after installation.

Warnings

Tools required

Parts

• ABS Hydraulic Control Module × 1 — Toyota 44050-42250 or equivalent
• Brake line crush washers (if applicable to connections) × 4 — Use OEM specification
• ABS module mounting gasket or seal (if equipped) × 1 — Check service manual for specific model year

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Ensure engine is completely cool if any previous driving has occurred.
3. Open hood and locate battery in engine compartment (driver side).
4. Disconnect negative battery terminal first, then positive terminal. Wait minimum 90 seconds for airbag system capacitor discharge.
5. Remove engine cover by pulling upward on cover (press-fit clips).
6. Locate ABS module mounted on driver side of engine compartment, near brake master cylinder on firewall.
7. Place catch pan under ABS module location to capture brake fluid spillage.
8. Have brake line plugs ready to immediately cap disconnected lines and minimize fluid loss.
9. Verify replacement ABS module part number matches original unit exactly - incorrect modules may cause brake system malfunction.

Procedure

1. 1

   Remove ABS Module Electrical Connectors
   Locate the two electrical connectors on the ABS module. Press the locking tab on the larger main connector and pull straight away from module. Repeat for the smaller secondary connector. Do not pull on wires - grasp connector body only. Inspect connectors for corrosion or damage; clean with electrical contact cleaner if necessary.
2. 2

   Label and Disconnect Brake Lines
   The ABS module has four brake line connections (one from master cylinder, three to wheel circuits). Using masking tape or labels, mark each brake line connection with its position (master, LF, RF, rear). Using 12mm flare nut wrench, carefully loosen each brake line fitting by turning counterclockwise. Work slowly to avoid rounding off fittings. Once loose, unthread by hand and immediately plug open ports on both lines and module with brake line plugs to minimize fluid loss and contamination.
   ⚠Use only flare nut wrenches on brake line fittings. Standard open-end wrenches will round off the soft brass fittings, requiring line replacement.
3. 3

   Remove ABS Module Mounting Hardware
   Locate the two ABS module mounting bolts securing the unit to the bracket on the firewall. These are 10mm bolts. Using 10mm socket, remove both mounting bolts completely. Support the module with one hand while removing the second bolt to prevent it from falling. Note the position of any bracket spacers or washers for reinstallation.
   Torque spec

   ABS Module Bolts10 Nm (7 lb-ft)
4. 4

   Remove Old ABS Module
   Carefully pull the ABS module away from the mounting bracket. Keep module upright to minimize brake fluid spillage from internal passages. Place old module in catch pan to contain any residual fluid. Inspect mounting bracket for damage or corrosion; clean if necessary. Check condition of any rubber isolation mounts or gaskets - replace if deteriorated.
5. 5

   Prepare New ABS Module
   Remove new ABS module from packaging. Verify part number matches original unit and vehicle application. Remove protective caps from brake line ports on new module. Inspect all ports for debris or damage. Do NOT remove caps until immediately before connecting lines. If module includes a mounting gasket or seal, position it correctly on the back of the module or on the mounting bracket per instructions.
6. 6

   Install New ABS Module
   Position new ABS module onto mounting bracket, aligning mounting bolt holes. Ensure any gasket or isolation mounts are properly seated. Insert both mounting bolts by hand and thread several turns to ensure proper engagement. Once both bolts are started, torque them in a cross pattern to 10.0 Nm (7.0 lb-ft) using torque wrench. Do not overtighten as this can crack the module housing.
   Torque spec

   ABS Module Bolts10 Nm (7 lb-ft)
7. 7

   Connect Brake Lines to ABS Module
   Remove plugs from brake line ends one at a time. Clean brake line fitting threads with wire brush if any contamination is visible. Thread each brake line fitting into the corresponding port on the ABS module by hand, using your labels to ensure correct position. Hand-tighten until snug, then use 12mm flare nut wrench to torque each fitting to 15.0 Nm (11.0 lb-ft). Work carefully to avoid cross-threading. Install all four brake lines in this manner.
   ⚠Thread brake line fittings carefully by hand first. Cross-threading will destroy the fitting and require brake line replacement. If fitting does not thread smoothly by hand, do not force it.
   Torque spec

   Brake Line Fittings15 Nm (11 lb-ft)
8. 8

   Reconnect Electrical Connectors
   Connect the two electrical connectors to the ABS module. Push each connector firmly onto the module until the locking tab clicks into place. Gently tug on each connector to verify it is fully seated and locked. Ensure no wires are pinched or under tension.
9. 9

   Refill Brake Fluid Reservoir
   Locate brake fluid reservoir on top of master cylinder. Clean area around reservoir cap before opening to prevent contamination. Remove cap and fill reservoir to MAX line with fresh DOT 3 brake fluid from a sealed container. Keep reservoir filled above MIN line throughout the bleeding procedure. Replace cap loosely to allow air to escape but prevent contamination.
10. 10

    Perform Manual Brake Bleeding
    Beginning with the wheel furthest from master cylinder (right rear, then left rear, then right front, then left front), attach clear tubing to bleeder screw and submerge other end in container with clean brake fluid. Have assistant pump brake pedal 3-5 times and hold pressure. Open bleeder screw 1/2 turn while pedal is held down, allow fluid and air to escape, then close bleeder screw before pedal reaches floor. Torque bleeder screw to 14.0 Nm (10.0 lb-ft). Repeat until no air bubbles appear in tubing. Maintain reservoir fluid level above MIN throughout process. Repeat for all four wheels in sequence.
    ⚠Never allow brake fluid reservoir to run dry during bleeding. Air entering the system will require restarting the entire bleeding procedure.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Reconnect Battery and Clear Codes
    Reconnect positive battery terminal first, then negative terminal. Turn ignition to ON position (do not start engine). ABS warning light should illuminate then extinguish after a few seconds. If ABS light remains on, proceed to next step for system initialization. If other brake warning lights are on, recheck all connections before proceeding.
12. 12

    Perform ABS System Initialization and Electronic Bleeding
    Connect Toyota Techstream diagnostic tool or equivalent OBD-II scanner with ABS bleeding capability to vehicle diagnostic port (located under driver side dashboard). Follow tool-specific procedures to access ABS bleeding function. The tool will cycle ABS solenoids and pump to purge air from ABS module internal passages. During this process, maintain brake fluid reservoir at MAX level. Tool will indicate when cycling is complete. After electronic bleeding, repeat manual bleeding procedure at all four wheels (step 10) to ensure any air released from ABS module is expelled from system.
    ⚠️Electronic ABS bleeding with diagnostic tool is MANDATORY. Manual bleeding alone cannot remove air from ABS module internal circuits. Skipping this step will result in ABS malfunction and potentially dangerous brake performance.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
13. 13

    Test Brake Pedal Feel
    With engine off, pump brake pedal several times. Pedal should feel firm and maintain pressure. If pedal feels soft or sinks slowly, air remains in system - repeat bleeding procedure. With engine running, apply firm brake pressure and hold for 30 seconds. Pedal should remain firm with no fade. ABS warning light should remain off during engine operation.
14. 14

    Final Fluid Level Check and System Inspection
    With engine off, check brake fluid reservoir level and top off to MAX line if needed. Securely tighten reservoir cap. Inspect all brake line connections at ABS module for any signs of leakage - wipe area clean and look for fresh fluid. Inspect electrical connectors for proper seating. Reinstall engine cover by aligning clips and pressing down firmly until it clicks into place.

Reassembly

1. Ensure all brake line fittings are torqued to specification and show no signs of leakage
2. Verify both ABS module electrical connectors are fully seated with locking tabs engaged
3. Confirm brake fluid reservoir is filled to MAX line with fresh DOT 3 fluid and cap is secure
4. Clear any stored diagnostic trouble codes using scan tool and verify ABS warning light extinguishes during normal operation
5. Engine cover should be reinstalled and properly seated on all mounting clips

Verification

• Start engine and verify ABS warning light illuminates briefly during self-test, then extinguishes. Light should remain off during operation.
• With engine running, apply firm brake pressure and verify pedal feels firm with no sponginess or excessive travel. Pedal should not sink slowly when held under pressure.
• Perform a careful low-speed test drive in a safe area. Apply brakes gently at first, then with increasing force to verify normal braking operation and proper pedal feel.
• CRITICAL: Perform ABS function test in a safe, clear area at low speed (15-20 mph). On dry pavement, apply firm brake pressure to intentionally activate ABS. You should feel pulsation in pedal and hear ABS pump cycling. This confirms ABS system is functioning correctly.
• After test drive, recheck brake fluid level and inspect all ABS module connections for any signs of leakage. Wipe area clean before inspection to identify fresh leaks.
• Use diagnostic scan tool to verify no ABS-related fault codes are present and all wheel speed sensors are reading correctly.
• If any warning lights remain on, brake pedal feels abnormal, or ABS does not activate during test, DO NOT drive vehicle. Repeat bleeding procedure or seek professional diagnosis.
• Dispose of used brake fluid properly according to local environmental regulations. Do not pour down drains or onto ground.

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