LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2020 >> Prius Limited >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information >> Brake Pedal >> Adjustment [11/2015 - 12/2018] >> Procedure

Adjustment [11/2015 - 12/2018]: Procedure

  1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT 
    1. Remove the front door scuff plate LH.

      Refer to PROCEDURE - Step 14

    2. Remove the cowl side trim board LH.

      Refer to PROCEDURE - Step 15

    3. Check the brake pedal height.
      NOTE:
      • Inspect and adjust the brake pedal height with the floor carpet folded back.
      • When performing the measurement, make sure that the measuring device is contacting the surface of the dash panel insulator assembly clip.
      1. Measure the shortest distance between the brake pedal pad surface and dash panel insulator assembly clip.
        GTY563143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Brake Pedal Pad - -
        *a Brake Pedal Height *b Dash Panel Insulator Assembly Clip
        *c 30 mm (1.18 in.) - -

        Brake Pedal Height from Dash Panel Insulator Assembly Clip

        174.3 to 184.3 mm (6.86 to 7.26 in.)

        If the pedal height is not as specified, adjust the brake pedal height according to the procedure below.

    4. Adjust the brake pedal height.
      1. Remove the stop light switch assembly.
        GTY571427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Stop Light Switch Assembly
        *2 Lock Nut
        *a Brake Pedal Height
        *b Dash Panel Insulator Assembly Clip

        Refer to REMOVAL [11/2015 - 12/2018]

      2. Loosen the lock nut.
      3. Adjust the brake pedal height by turning the push rod.

        Brake Pedal Height from Dash Panel Insulator Assembly Clip

        174.3 to 184.3 mm (6.86 to 7.26 in.)

      4. Tighten the lock nut.

        Torque: 25.5 N.m (260 kgf.cm, 19 ft./lbf) 

      5. Install the stop light switch assembly.

        Refer to INSTALLATION [11/2015 - ]

    5. Install the cowl side trim board LH.

      Refer to PROCEDURE - Step 50

    6. Install the front door scuff plate LH.

      Refer to PROCEDURE - Step 51

  2. INSPECT AND ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY 
    1. Inspect the brake pedal stroke sensor assembly.
      1. Connect the Techstream to the DLC3 with the power switch off.
      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.

        Chassis > ABS/VSC/TRAC > Data List 

        Tester Display
        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. Remove the front door scuff plate LH.

        Refer to PROCEDURE - Step 14

      2. Remove the cowl side trim board LH.

        Refer to PROCEDURE - Step 15

      3. Remove the No. 1 instrument panel under cover sub-assembly.

        Refer to PROCEDURE - Step 9 [11/2015 - 11/2017] , or refer to PROCEDURE - Step 9 [11/2017 - 12/2018]

      4. Loosen the 2 nuts.
        GTY557798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

      5. 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.
        GTY601786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Voltage (without the brake pedal depressed)

        0.8 to 1.2 V

      6. Tighten the 2 nuts.

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

      7. Turn the Techstream off and turn the power switch off.
      8. Disconnect the Techstream.
      9. Install the No. 1 instrument panel under cover sub-assembly.

        Refer to PROCEDURE - Step 22 [11/2015 - 11/2017] , or refer to PROCEDURE - Step 24 [11/2017 - 08/2019]

      10. Install the cowl side trim board LH.

        Refer to PROCEDURE - Step 50

      11. Install the front door scuff plate LH.

        Refer to PROCEDURE - Step 51

    3. Perform linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization.

      Refer to INITIALIZATION [11/2015 - 12/2018]

  3. INSPECT BRAKE PEDAL FREE PLAY 
    1. Depress the brake pedal until a slight resistance is felt. Measure the brake pedal free play as shown in the illustration.
      GTY452630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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 1

      If the pedal free play is as specified, proceed to the Inspect Brake Pedal Reserve Distance procedure.

  4. INSPECT BRAKE PEDAL RESERVE DISTANCE 
    1. Remove the front door scuff plate LH.

      Refer to PROCEDURE - Step 14

    2. Remove the cowl side trim board LH.

      Refer to PROCEDURE - Step 15

    3. Turn back the front floor carpet assembly.
    4. Cut each claw of the 2 clips and remove the No. 1 dash panel insulator pad.
      GTY687942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cut
      NOTE:

      If the No. 1 dash panel insulator pad is damaged, replace it with a new one.

    5. Remove the 2 clips.
    6. With the power switch on (READY), depress the brake pedal and measure the brake pedal reserve distance.
      GTY710603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Pedal Pad - -
      *a Brake Pedal Reserve Distance *b Floor Panel
      *c 30 mm (1.18 in.) - -

      Brake Pedal Reserve Distance from Floor Panel at 300 N (31 kgf, 67.4 lbf)

      115 mm (4.53 in.) or more

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

      Refer to PROBLEM SYMPTOMS TABLE [11/2015 - ]

    7. Install the No. 1 dash panel insulator pad with 2 new clips as shown in the illustration.
      GTY736630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the front floor carpet assembly to its original position.
    9. Install the cowl side trim board LH.

      Refer to PROCEDURE - Step 50

    10. Install the front door scuff plate LH.

      Refer to PROCEDURE - Step 51

scientia non olet · About LEMON Manuals