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Brake System: Adjustment

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 

    Hatchback: See REMOVAL

    Sedan: See REMOVAL

  2. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY 

    Hatchback: See REMOVAL

    Sedan: See REMOVAL

  3. INSPECT AND ADJUST BRAKE PEDAL 
    1. Inspect the brake pedal height.

      Pedal height from floor 

      BRAKE PEDAL HEIGHT SPECIFICATION

      w/ ABS w/o ABS
      107.3 to 117.3 mm (4.224 to 4.618 in.) 107.8 to 117.8 mm (4.244 to 4.638 in.)

      If the pedal height is incorrect, adjust it.

    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. Loosen the push rod lock nut.
      4. Adjust the pedal height by turning the pedal push rod.

        Pedal height from floor 

        Fig 1: Identifying Brake Pedal Height From Floor
        G04832257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        BRAKE PEDAL HEIGHT SPECIFICATION

        w/ ABS w/o ABS
        107.3 to 117.3 mm (4.224 to 4.618 in.) 107.8 to 117.8 mm (4.244 to 4.638 in.)
      5. Tighten the push rod lock nut.

        Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      6. Insert the stop light switch into the adjuster until it just touches the brake pedal.
        NOTE: Do not depress the brake pedal.
        Fig 2: Identifying Stop Light Switch, Adjuster & Brake Pedal
        G04832258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. 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 

      8. Check the stop light switch clearance.

        Stop light switch clearance: 

        0.5 to 2.6 mm (0.020 to 0.102 in.) 

      9. Connect the connector to the stop light switch.
        Fig 3: Identifying Stop Light Switch Clearance
        G04832259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Inspect the brake pedal free play.
      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.

        Fig 4: Identifying Brake Pedal Free Play
        G04832260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Inspect the brake pedal reserve distance.
      1. Release the parking brake lever. With the engine running, depress the pedal and measure the pedal reserve distance as shown.

        Pedal reserve distance from floor at 294 N (30 kgf, 66.1 lbf) 

        PEDAL RESERVE DISTANCE SPECIFICATION

        w/ ABS w/o ABS
        More than 73 mm (2.87 in.) More than 70 mm (2.75 in.)

        HINT:

        Sound and resistance from the brake booster when the brake pedal is depressed without a vacuum does not indicate a problem.

        If incorrect, troubleshoot the brake system.

        Fig 5: Identifying Brake Pedal Reserve Distance
        G04832261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY 

    Hatchback: See INSTALLATION

    Sedan: See INSTALLATION

  5. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 

    Hatchback: See INSTALLATION

    Sedan: See INSTALLATION

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