Brake Pedal Support ASSY: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Check brake pedal height.
  Pedal height from asphalt sheet:
  
  143.3 to 153.3 mm (5.641 to 6.035 in.)
2. Adjust brake pedal height.
  1. Remove instrument panel sub-assy LWR No.1 and instrument panel airbag assy LWR No.1.
  2. Disconnect the stop light switch assy connector from the stop light switch assy.
  3. Turn the stop light switch assy counterclockwise and remove the stop light switch assy.
  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)
    
    Fig 1: Adjusting Pedal Height By Turning Pedal Push Rod
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Insert the stop light switch assy until the body hits the cushion.
    NOTE: When inserting the stop light switch assy, support the pedal from behind so that the pedal is not pushed in.
    
    Fig 2: Inserting Stop Light Switch Assy Until Body Hits Cushion
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Make a quarter turn clockwise to install the stop light switch assy.
    NOTE:
    When inserting the stop light switch assy, support the pedal from behind so that the pedal is not pushed in.
    
    The turning torque for installing the stop light switch assy.
    Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf) or less
  8. Connect the stop light switch connector to the stop light switch assy.
  9. Check the protrusion of the rod.
    Protrusion of the rod:
    
    0.5 to 2.5 mm (0.020 to 0.098 in.)
  10. Install instrument panel sub-assy LWR No.1 and instrument panel airbag assy LWR No.1.
    
    Fig 3: Installing Stop Light Switch Assy
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PEDAL FREE PLAY
1. Stop the engine and depress the brake pedal several times until no vacuum remains in the booster.
2. Press the pedal until resistance is felt. Measure the distance as shown in the illustration.
  Pedal free play:
  
  1.0 to 6.0 mm (0.039 to 0.236 in.)
  
  If incorrect, proceed to the following step.
  1. Check the stop light switch clearance.
  Stop light switch clearance:
  
  0.5 to 2.5 mm (0.020 to 0.098 in.)
  
  If correct, the pedal free play is OK.
  
  If incorrect, adjust the stop light switch clearance.
  
  Fig 4: Checking Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PEDAL RESERVE DISTANCE
1. Release the parking brake pedal.
  With the engine running, depress the brake pedal and measure the pedal reserve distance as shown in the illustration.
  
  Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbf):
  
  More than 77 mm (3.0 in.)
  
  If incorrect, troubleshoot the brake system.
  
  Fig 5: Checking Pedal Reserve Distance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002