Brake Pedal Sub-ASSY: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Check brake pedal height.
  Pedal height from asphalt sheet:
  
  150.0 to 160.0 mm (5.906 to 6.299 in.)
2. Adjust brake pedal height.
  1. Disconnect the connector from the stop lamp switch assy.
  2. Loosen the stop lamp switch lock nut and remove the stop lamp switch assy.
  3. Loosen the push rod lock nut.
  4. Adjust the pedal height by turning the pedal push rod.
  5. Tighten the push rod lock nut.
    Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
  6. Install the stop lamp switch assy.
  7. Connect the connector to the stop lamp switch assy.
  8. Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off.
  9. After installation, push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that the stop lamp comes on.
  10. Tighten the stop lamp switch lock nut.
    Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
CHECK PEDAL FREE PLAY
1. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
2. Press the pedal until the beginning of the resistance is felt. Measure the distance as shown in the illustration.
  Pedal freeplay: 2.0 to 3.0 mm (0.079 to 0.118 in.)
  
  Fig 2: Checking Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If incorrect, proceed to the following step.
  1. Check the stop lamp switch clearance.
    Stop lamp switch clearance:
    
    0.5 to 2.6 mm (0.020 to 0.102 in.)
    
    If correct, the pedal free play is OK.
    
    If incorrect, adjust the stop lamp switch clearance.
CHECK PEDAL RESERVE DISTANCE
1. Release the parking brake pedal.
2. With engine running, depress the pedal and measure the pedal reserve distance, as shown.
  Pedal reserve distance from asphalt sheet at 490 N
  
  (50 kgf, 110.2 lbf): More than 80 mm (3.1 in.)
  
  If incorrect, troubleshoot the brake system.