On-Vehicle Inspection

INSPECT AND ADJUST BRAKE PEDAL
1. Inspect the brake pedal height.
  Pedal height from dash panel:
  
  168.7 to 178.7 mm (6.642 to 7.035 In.)
  
  If the pedal height is incorrect, adjust the rod operating adapter length.
  
  Fig 1: Identifying Pedal Height From Dash Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Adjust the brake pedal height.
  1. Disconnect the connector from the stop light switch.
  2. Turn the stop light switch counterclockwise, and remove the stop light switch.
  3. Remove the hydraulic brake booster (See REMOVAL ).
  4. Loosen the clevis lock nut.
  5. Adjust the rod operating adapter length by turning the pedal push rod clevis.
    Rod operating adapter length A:
    
    201.7 to 202.7 mm (7.941 to 7.980 in.)
    
    Fig 2: Identifying Rod Operating Adapter Length
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Tighten the clevis lock nut.
    Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
  7. Install the hydraulic brake booster (See INSTALLATION ).
  8. Insert the stop light switch into the adjuster until it just touches the brake pedal.
    NOTE: Do not depress the brake pedal.
    
    Fig 3: Identifying Stop Light Switch And Adjuster
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Make a quarter turn clockwise to install the stop light switch.
    NOTE: Do not depress the brake pedal.
    
    HINT:
    
    The turning torque for installing the stop light switch:
    
    Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
    
    Fig 4: Identifying Stop Light Switch Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Check the stop light switch clearance.
    Stop light switch clearance:
    
    0.5 to 2.6 mm (0.020 to 0.102 in.)
  11. Connect the connector to the stop light switch.
3. Inspect the brake pedal free play.
  
  Fig 5: Identifying Brake Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Stop the engine and depress the brake pedal several times until there is no vacuum left in the booster.
  2. Push in the pedal until the beginning of the resistance is felt. Measure the distance as shown.
    Pedal free play:
    
    1.0 to 6.0 mm (0.039 to 0.236 in.)
    
    If incorrect, troubleshoot the brake system.
4. Inspect the brake pedal reserve distance.
  
  Fig 6: Identifying Pedal Reserve Distance From Asphalt Sheet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Release the parking brake pedal.
    With the engine running, depress the pedal and measure the pedal reserve distance as shown.
    
    Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf):
    
    More than 56 mm (2.20 in.)
    
    If incorrect, troubleshoot the brake system.