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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information - (Hybrid) >> Brake Pedal >> Adjustment [10/2014 - ] >> Procedure

Adjustment [10/2014 - ]: Procedure

  1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT 
    1. Check the brake pedal height.
      1. Turn back the carpet.
      2. Turn back the dash panel insulator assembly from the slit provided on the dash panel insulator assembly.
      3. Measure the shortest distance between the brake pedal pad surface and floor panel.
        GTY322665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Stop Light Switch Assembly
        *2 Floor Panel
        *a Brake Pedal Height

        Brake Pedal Height from Floor Panel

        138.5 to 148.5 mm (5.46 to 5.84 in.)

        If pedal height is incorrect, inspect and adjust the push rod length according to the procedure below.

    2. Adjust the push rod length.
      1. Remove the stop light switch assembly (Refer to PROCEDURE - Step 1 ).
      2. Remove the brake booster with master cylinder assembly (Refer to REMOVAL [10/2014 - ] ).
      3. Loosen the lock nut and adjust the push rod length shown in the illustration by turning the brake master cylinder push rod clevis to achieve the correct length.
        GTY566140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Lock Nut
        *2 Brake Master Cylinder Push Rod Clevis
        *a Push Rod Length

        Push Rod Length

        115.5 to 116.5 mm (4.55 to 4.58 in.)

      4. Tighten the lock nut.

        Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      5. Install the brake booster with master cylinder assembly (Refer to INSTALLATION [10/2014 - ] ).
        • If the pedal height is incorrect even when the push rod length is adjusted, check the brake pedal support assembly and floor panel.
        • If necessary, replace the brake pedal support assembly.
      6. Install the stop light switch assembly (Refer to PROCEDURE - Step 2 ).
    3. After adjusting the pedal height, check the brake pedal free play.
  2. INSPECT AND ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY 
    1. Inspect the brake pedal strike sensor assembly.
      1. Connect the Techstream to the DLC3.
      2. Turn the power switch on (IG).
      3. Turn the Techstream on and enter the following menus: Chassis / ABS/VSC/TRAC / Data List / Stroke Sensor.
      4. Read the stroke sensor value without the brake pedal depressed.

        Standard Voltage (without the brake pedal depressed)

        0.8 to 1.2 V

        If the stroke sensor value is not within the standard voltage, adjust the brake pedal stroke sensor assembly.

    2. Adjust the brake pedal stroke sensor assembly.
      1. Loosen the 2 bolts.
        GTY323136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Read the stroke sensor value in the Data List, and turn the brake pedal stroke sensor assembly slowly to the right or left to adjust the output voltage so that it is within the following range.
        GTY539304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Voltage (without the brake pedal depressed)

        0.8 to 1.2 V

      3. Tighten the 2 bolts.
        GTY323136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

        NOTE:

        Do not depress the brake pedal after turning the power switch on (IG).

      4. Turn the Techstream off and turn the power switch off.
      5. Disconnect the Techstream.
  3. INSPECT BRAKE PEDAL FREE PLAY 
    1. Depress the pedal until a slight resistance is felt. Measure the brake pedal free play as shown in the illustration.
      GTY605668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Brake Pedal Free Play

      Brake Pedal Free Play

      1.0 to 6.0 mm (0.0394 to 0.236 in.)

      If the pedal free play is not as specified, check the stop light switch clearance (Refer to PROCEDURE - Step 2 ). If the pedal free play is as specified, proceed to the Inspect Brake Pedal Reserve Distance procedure.

  4. INSPECT BRAKE PEDAL RESERVE DISTANCE 

    HINT: 

    Measure the distance at the same point used for the brake pedal height inspection.

    1. Release the parking brake.
    2. With the power switch on (READY), depress the brake pedal and measure the pedal reserve distance.

      Brake Pedal Reserve Distance from Floor Panel at 500 N (51 kgf, 112 lbf)

      More than 92 mm (3.62 in.)

      If the distance is not as specified, troubleshoot the brake system (Refer to PROBLEM SYMPTOMS TABLE [10/2014 - ] ).

  5. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE 

    (Refer to INITIALIZATION [10/2014 - ] )

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