On-Vehicle Inspection

Pedal height from asphalt sheet: 

150.0 - 160.0 mm (5.906 - 6.299 in.) 

1. Remove the No. 1 under cover, end pad, No. 1 safety pad and No. 7 heater to register duct (See INSTRUMENT PANEL ).
2. Disconnect the connector from the stop light switch.
3. Loosen the stop light switch lock nut and remove the stop light switch.
4. Loosen the push rod lock nut.
5. Adjust the pedal height by turning the pedal push rod.
6. Tighten the push rod lock nut.

   Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) 

   Fig 1: Identifying Pedal Height

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the stop light switch.
8. Connect the connector to the stop light switch.
9. Push in the brake pedal 5 - 15 mm (0.20 - 0.59 in.), turn the stop light switch to lock the nut in the position where the stop light goes off.
10. After installation, push in the brake pedal 5 - 15 mm (0.200.59 in.), check that stop light lights up.
11. After adjusting the pedal height, check the pedal freeplay.
12. Install the No. 7 heater to register duct, No. 1 safety pad, end pad and No. 1 under cover.

1. Stop the engine and depress the brake pedal more than times until there is no more pressure left in the booster.
2. Push in the pedal by hand until the second point of resistance begins to be felt, then measure the distance, as shown.

   Pedal freeplay: 0.2 - 2.0 mm (0.008 - 0.079 in.) 

   Fig 2: Identifying Pedal Freeplay

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system.

   Stop light switch clearance: 

   0.5 - 2.4 mm (0.020 - 0.094 in.) 

   HINT:

   The freeplay to the 1st point of resistance is due to the play between the clevis and pin. It is 0.2 - 2.0 mm (0.008 - 0.079 in.) on the pedal.

1. Remove the floor carpet.
2. Release the parking brake.
3. With the engine running, depress the pedal and measure the pedal reserve distance, as shown.

   Pedal reserve distance at 196 N (20 kgf, 44.1 lbf): 

   Fig 3: Identifying Pedal Reserve Distance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   More than 93 mm (3.66 in.) 

4. If the reserve distance is incorrect, troubleshoot the brake system.
5. Install the floor carpet.