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Home >> Toyota >> 2021 >> RAV4 Prime XSE >> Repair and Diagnosis >> Brakes >> Traction Control >> Brake Control System - Service Information (PHEV) >> Brake Pedal Stroke Sensor >> Installation [06/2020 - 10/2022] >> Procedure

Installation [06/2020 - 10/2022]: Procedure

  1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT 

    Refer to ADJUSTMENT [06/2020 - ]

  2. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY 
    NOTE:
    • Do not drop the brake pedal stroke sensor assembly.
    • If the brake pedal stroke sensor assembly has been dropped, replace the brake pedal stroke sensor assembly with a new one.
    1. When installing a new brake pedal stroke sensor assembly:
      NOTE:

      Do not break the brake pedal stroke sensor assembly lever set pin before installing the brake pedal stroke sensor assembly with the 2 nuts.

      1. Install a new brake pedal stroke sensor assembly to the brake pedal support assembly with the 2 nuts.
        NOTE:
        • Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.
        • Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor assembly.
        • Check that the tip of the brake pedal stroke sensor assembly lever is protruding from the brake pedal groove.
        GTY977081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Brake Pedal Stroke Sensor Assembly Lever
        *b Brake Pedal Groove
        *c Brake Pedal Stroke Sensor Assembly Lever Set Pin
        *d Torque Wrench Fulcrum Length
      2. Fully tighten the nut (A).

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

      3. Using SST, fully tighten the nut (B).
        • SST: 09961-00950 

        Specified tightening torque 

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

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [06/2020 - ]

        • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 185 mm (7.28 in.)):

          4.7 N.m (48 kgf/cm, 42 in.lbf)

      4. Connect the connector.
      5. Firmly depress the brake pedal to break the brake pedal stroke sensor assembly lever set pin.
      6. Remove the broken lever set pin.
    2. When reusing the brake pedal stroke sensor assembly:
      1. Install the brake pedal stroke sensor assembly to the brake pedal support assembly and temporarily tighten the 2 nuts.
        NOTE:
        • Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.
        • Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor assembly.
        • Check that the tip of the brake pedal stroke sensor assembly lever is protruding from the brake pedal groove.
        GTY973342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Brake Pedal Stroke Sensor Assembly Lever
        *b Brake Pedal Groove
      2. Connect the connector.
  3. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to INSTALLATION [06/2020 - 10/2022]

  4. ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY 
    NOTE:
    • When the brake pedal stroke sensor assembly is being reused, perform the following procedure to adjust it.
    • Do not depress the brake pedal after turning the ignition switch to ON.
    1. 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.

      Chassis > Brake Booster > Data List 

      Tester Display
      Stroke Sensor
      GTY975831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length

      Standard Voltage (without the brake pedal depressed)

      0.8 to 1.2 V

    2. Fully tighten the nut (A).

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

    3. Using SST, fully tighten the nut (B).
      • SST: 09961-00950 

      Specified tightening torque 

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

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [06/2020 - ]

      • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 185 mm (7.28 in.)):

        4.7 N.m (48 kgf/cm, 42 in.lbf)

  5. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 24

  6. INSTALL COWL SIDE TRIM BOARD LH 

    Refer to PROCEDURE - Step 14 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 14 [12/2021 - 10/2022]

  7. INSTALL FRONT DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 40 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 40 [12/2021 - ]

  8. PERFORM CALIBRATION 

    Refer to UTILITY [06/2020 - ]

  9. CHECK AND CLEAR DTC 

    Refer to DTC CHECK / CLEAR [06/2020 - ]

  10. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    Refer to WORK PROCEDURE [06/2020 - 10/2022]

    HINT: 

    When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [06/2020 - 12/2021] , or refer to AUTOMATIC LEARNING CHART [12/2021 - ]

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