Brake Pedal: Adjustment

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CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Check the pedal height.
  Standard pedal height from dash panel: 184.2 to 194.2 mm (7.252 to 7.646 in.)
2. Adjust the pedal height.
  1. Disconnect the connector from the stop light switch.
  2. Remove the switch.
  3. Loosen the push rod clevis lock nut.
  4. Adjust the pedal height by turning the push rod.
  5. Tighten the lock nut.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
    
    Fig 1: Adjusting Pedal Height
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Insert the switch into the adjuster until the switch body touches the pedal.
    NOTE: Do not depress the pedal.
    
    Fig 2: Inserting Switch Into Adjuster
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Turn the switch a quarter turn clockwise.
    Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
    
    NOTE: Do not depress the pedal.
  8. Connect the connector to the switch.
  9. Check the switch clearance.
    Standard stop light switch clearance: 1.5 to 2.5 mm (0.059 to 0.098 in.)
    
    Fig 3: Checking Switch Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK BRAKE PEDAL FREE PLAY
1. Stop the engine. Depress the pedal several times until there is no vacuum in the booster. Then release the pedal.
2. Depress the pedal until resistance is felt.
3. Check the pedal's free play by measuring the distance between the position in the previous step and the pedal's released position.
  Standard pedal free play: 1.0 to 6.0 mm (0.039 to 0.236 in.)
  
  If the free play is not as specified, check the switch clearance in the next step.
  
  If the free play is as specified, proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure in step 3.
  
  Fig 4: Checking Brake Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the switch clearance.
  Standard stop light switch clearance: 1.5 to 2.5 mm (0.059 to 0.098 in.)
  
  If the clearance is not as specified, reinstall the switch and recheck the pedal's free play.
  
  If the clearance is as specified, troubleshoot the brake system and proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure in step 3.

CHECK BRAKE PEDAL RESERVE DISTANCE

Release the parking brake lever. Start the engine.

Depress the pedal and check the pedal reserve distance.

Depress the pedal with a force of 490 N (50 kgf, 110 lbf).

Measure the distance between the pedal and dash panel shown in the illustration.

Standard pedal reserve distance

BRAKE PEDAL RESERVE DISTANCE

Engine	Specified Condition
2AZ-FE (w/o 3rd seat)	More than 95 mm (3.74 in.)
2AZ-FE (w/3rd seat)	More than 120 mm (4.72 in.)
2GR-FE	More than 120 mm (4.72 in.)

Fig 5: Checking Brake Pedal Reserve Distance

If the distance is not as specified, troubleshoot the brake system.