Brake Pedal: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Check the brake pedal height.
  Pedal height from asphalt sheet: 143.3 to 153.3 mm (5.641 to 6.035 in.)
  
  Fig 1: Identifying Brake Pedal Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Adjust the brake pedal height.
  1. Remove the 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 contacts 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 Until Body Contacts Cushion
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Rotate the switch a quarter turn clockwise to install it.
    NOTE: When installing the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.
    
    Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
    
    Fig 3: Identifying Stop Light Switch Clearance And Cushion
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 2.6 mm (0.020 to 0.102 in.)
  10. Install the instrument panel sub-assembly LWR No.1 and instrument panel airbag assembly LWR No.1.
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.
  
  Fig 4: Checking Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.)
    
    HINT:
    
    If the clearance is not as specified, adjust the stop light switch clearance and recheck pedal free play. If the clearance is as specified, proceed to the following "CHECK PEDAL RESERVE DISTANCE" procedure.
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: Measuring Pedal Reserve Distance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002