Brake Pedal: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
NOTE: Pull up the floor carpet and dash panel insulator, and then check and adjust the brake pedal height.
1. Remove the lower instrument panel finish panel (See REMOVAL ).
2. Inspect brake pedal height.
  Pedal height from the top of the asphalt sheet: 138 to 148 mm (5.433 to 5.827 in.)
3. Adjust brake pedal height.
  1. Disconnect the connector from the stop light switch.
  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. Turn the push rod and adjust the pedal height.
  4. Tighten the clevis lock nut.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
    
    Fig 1: Adjusting Brake Pedal Height
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Turn the stop light switch so that the clearance between its thread portion tip and the area where the pedal makes contact is between 0.5 to 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
    
    Fig 2: Adjusting Stop Light Switch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Connect the connector to the stop light switch.
  7. Connect the intelligent tester to the DLC3.
  8. Loosen the stroke sensor set bolts.
  9. Turn the power switch ON (IG). Read the stroke sensor 1 value displayed on the data monitor using the intelligent tester. Slowly turn the stroke sensor to the right and left to adjust it to the standard value.
    Standard voltage: 0.8 to 1.2 V
    
    Fig 3: Adjusting Brake Pedal Stroke Sensor
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Tighten the stroke sensor set bolts.
    Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
    
    CAUTION: Do not depress the brake pedal after the power switch turns ON (IG).
  11. Carry out system initialization (see INITIALIZATION ).
4. Install lower instrument panel finish panel (See INSTALLATION ).
CHECK BRAKE PEDAL FREE PLAY
1. Depress the brake pedal several times strongly after the engine stops.
2. Check the brake pedal free play.
  Standard pedal free play: 0.5 to 4 mm (0.02 to 0.16 in.)
  
  If incorrect, proceed to the following step.
  1. Check the stop light switch clearance.
    Standard stop light switch clearance: 0.5 to 2.4 mm (0.020 to 0.095 in.)
    
    If the clearance is OK, then troubleshoot the brake system.
    
    If incorrect, adjust the stop light switch clearance.
    
    Fig 4: Identifying Brake Pedal Free Play
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK BRAKE PEDAL RESERVE DISTANCE
1. Release the parking brake pedal.
2. With engine running, depress the pedal and measure the pedal reserve distance, as shown in Fig 5.
  Standard pedal reserve distance (from the top of the asphalt sheet): 196 N (20 kgf, 44.1 lbf): More than 104 mm (4.1 in.)
  
  NOTE: Pull up the floor carpet and dash panel insulator, and then check the brake pedal reserve distance.
  
  If incorrect, troubleshoot the brake system.
  
  Fig 5: Checking Brake Pedal Reserve Distance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002