On-Vehicle Inspection

Pedal height from asphalt sheet: 183.7 - 193.7 mm (7.232 - 7.626 in.) 

If the pedal height is incorrect, adjust it.

Fig 1: Checking Pedal Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the scuff plate, cowl side trim, lower No. 1 panel, LH lower panel and No. 2 heater to register duct (See COMPONENTS ).
2. Remove the steering wheel pad, steering wheel lower No. 2 and No. 3 covers, steering wheel, combination switch, column upper and lower covers, steering column assembly and thrust stopper (See REMOVAL or REMOVAL ).
3. Disconnect the connector from the stop light switch.
4. Loosen the stop light switch lock nut and remove the stop light switch.
5. Loosen the push rod lock nut.
6. Adjust the pedal height by turning the pedal push rod.
7. Tighten the push rod lock nut.

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

8. Install the stop light switch.
9. Connect the connector to the stop light switch.
10. 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.
11. After installation, push in the brake pedal 5 - 15 mm (0.20 - 0.59 in.), check that stop light lights up.
12. After adjusting the pedal height, check the pedal freeplay.
13. Install the thrust stopper, steering column assembly, column upper and lower covers, combination switch, steering wheel, steering wheel lower No. 2 and No. 3 covers, and steering wheel pad (See INSTALLATION or INSTALLATION ).
14. Install the No. 2 heater to register duct, LH lower panel, lower No. 1 panel, cowl side trim and scuff plate (See COMPONENTS ).

1. Stop the engine and depress the brake pedal more than 40 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 in Fig 2.

   Pedal freeplay: 1.0 - 6.0 mm (0.039 - 0.236 in.) 

   Fig 2: Measuring Brake Pedal Distance

   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: 1.9 mm (0.075 in.) 

   HINT:

   The freeplay to the 1st point of resistance is due to the play between the clevis, pedal link and pin. It is 1.0 - 6.0 mm (0.039 - 0.236 in.) on the pedal.

1. Remove the floor carpet.
2. Release the parking brake.

   With the engine running, depress the pedal and measure the pedal reserve distance, as shown in Fig 3.

   Pedal reserve distance at 490 N (50 kgf, 110.1 lbf): More than 116 mm (4.57 in.) 

   If the reserve distance is incorrect, troubleshoot the brake system.

   Fig 3: Measuring Pedal Reserve Distance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002