On-Vehicle Inspection

Fig 1: Displaying Brake Pedal

Check pedal height.
Pedal height from asphalt sheet:

158.1-168.1 mm (6.224-6.618 in.)
If necessary, adjust pedal height.
1. Remove the lower finish 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 clevis lock nut.
5. Adjust the pedal height by turning the pedal push rod.
6. Tighten the clevis lock nut.
  1. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf)
7. Install the stop light switch.
8. Connect the connector to the stop light switch.
9. Push the brake pedal in 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. Push the brake pedal in 5-15 mm (0.20-0.59 in.), check that stop light lights up.
11. After adjusting the pedal height, check the pedal freeplay.
12. Install the lower finish panel.
Check pedal freeplay.
1. Stop the engine and depress the brake pedal several times until there is no more pressure left in the booster.
2. Push in the pedal by hand until the beginning of the second resistance is felt. Measure the distance.
  1. Pedal freeplay: 1-6 mm (0.12-0.24 in.)
NOTE:
1. The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 1-3 mm (0.04-0.12 in.) at the pedal.
2. If incorrect, check the stop light switch clearance.
3. If the clearance is OK, then troubleshoot the brake system.
  1. Stop light switch clearance: 0.5-2.4 mm (0.020-0.094 in.)
Check pedal reserve distance.

Fig 3: Displaying Pedal Reverse Distance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown.
1. Pedal reserve distance, "A", at 490 N (50 kgf, 110.2 lbf): More than 75 mm (2.83 in.)
If incorrect, troubleshoot the brake system.