Brake Pedal: 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.
  
  Fig 1: Adjusting Brake Pedal Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Remove instrument panel sub-assembly LWR No. 1 and instrument panel airbag assembly LWR No. 1.
  2. Disconnect the stop light switch assembly connector from the stop light switch assembly.
  3. Turn the stop light switch assembly counterclockwise and remove the stop light switch assembly.
  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. Insert the stop light switch assembly until the body hits the cushion.
    NOTE: When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.
    
    Fig 2: Inserting Stop Light Switch Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Make a quarter turn clockwise to install the stop light switch assembly.
    NOTE:
    When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.
    
    The turning torque for installing the stop light switch assembly.
    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 assembly.
  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-assembly LWR No. 1 and instrument panel airbag assembly LWR No. 1.
Fig 3: Making Quarter Turn To Install Stop Light Switch Assembly
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: Measuring Distance
    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