Brake Pedal: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
NOTE: Perform check and adjustment with the rug removed.
1. Check the brake pedal height.
2. Adjust the brake pedal height.
  1. Disconnect the connector from the stop light switch assembly.
  2. Loosen the stop light switch lock nut. Turn the switch in order to give the pedal some free play.
  3. Loosen the clevis lock nut.
  4. Adjust the pedal height by turning the pedal push rod.
    Pedal height from the silencer pad:
    
    144.7 to 154.7 mm (5.697 to 6.090 in.)
  5. Tighten the clevis lock nut.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
    
    Fig 1: Identifying Brake Pedal Height
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Turn the stop light switch assembly so that the clearance between the nut end and the stop light switch cushion is between 0.5 and 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.
    Torque: 16.7 N*m (170 kgf*cm, 12 ft.*lbf)
  7. Connect the connector to the stop light switch assembly.
ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY
1. Connect the Techstream to the DLC3.
2. Loosen the 2 bolts.
3. Turn the ignition switch to the ON position. Reading the stroke sensor 1 value shown on the Techstream screen, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
  Standard voltage:
  
  0.8 to 1.2 V
  
  Fig 2: Turning Ignition Switch To ON Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 2 bolts.
  Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
  
  NOTE: Do not depress the brake pedal after turning the ignition switch to the ON position.
5. Perform system initialization. (See INITIALIZATION )
CHECK PEDAL FREE PLAY
1. Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.
  Pedal free play:
  
  1 to 2 mm (0.039 to 0.079 in.)
  1. If the pedal free play is 1.0 mm (0.039 in.) or less, check the protrusion of the stop light switch assembly shaft.
  Fig 3: Identifying Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Protrusion of the stop light switch assembly shaft:
  
  0.5 to 2.4 mm (0.020 to 0.095 in.)
  
  HINT:
  - Adjust if the protrusion is off the specified value.
  - If the protrusion is within the specified value, it is normal though brake pedal free play is 1.0 mm (0.039 in.) or less.
CHECK PEDAL RESERVE DISTANCE
1. Release the parking brake pedal.
2. With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.
Fig 4: Identifying Pedal Reserve Distance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Pedal reserve distance from the dash panel at 490 N (50 kgf, 110 lbf):

More than 90 mm (3.54 in.)