Brake Pedal Support

CHECK AND ADJUST BRAKE PEDAL HEIGHT
NOTE:
Fold back the carpet below the brake pedal for this inspection adjustment.
1. Check the brake pedal height.
  
  Fig 1: Identifying Brake Pedal Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard pedal height from No. 2 Dash Panel Insulator Pad
  
  144.2 to 154.2 mm (5.68 to 6.07 in.)
2. Adjust the pedal height.
  1. Disconnect the connector from the stop light switch.
  2. Loosen the stop light switch lock nut and turn the switch so that the pedal has free play.
  3. Loosen the push rod clevis lock nut.
  4. Adjust the pedal height by turning the push rod.
    Standard pedal height from No. 2 Dash Panel Insulator Pad
    
    144.2 to 154.2 mm (5.68 to 6.07 in.)
  5. Tighten the push rod clevis lock nut.
    Torque
    
    26 Nm (265 kgf cm, 19 ft.lbf)
  6. Turn the stop light switch so that its protrusion is between 1.5 and 2.6 mm (0.059 and 0.102 in.). Then tighten the lock nut.
    
    Fig 2: Identifying Stop Light Switch Lock Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque
    
    17 Nm (170 kgf cm, 12 ft. lbf)
  7. Connect the stop light switch connector.
  8. Without depressing the brake pedal, check that the stop light does not illuminate. If it illuminates, adjust the brake pedal height again.
  9. Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that the stop light comes on.
  If the stop light does not turn on, adjust the brake pedal height again.
ADJUST BRAKE PEDAL STROKE SENSOR
1. Connect the Techstream to the DLC3 with the power switch OFF.
2. Loosen the 2 bolts.
  
  Fig 3: Turning Stroke Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the power switch ON (IG). While reading the stroke sensor 1 value shown on the Techstream, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
  Standard voltage
  
  0.8 to 1.2 V
4. Tighten the 2 bolts.
  Torque
  
  8.5 Nm (87 kgf cm, 75ft. lbf)
  
  NOTE:
  Do not depress the brake pedal while performing the linear valve offset learning, as this may cause a DTC to be stored.
5. Perform the linear valve offset learning.
CHECK BRAKE PEDAL FREE PLAY
1. Press the pedal until a slight resistance is felt.
  Measure the distance as shown in the illustration.
  
  Fig 4: Identifying Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard pedal free play
  
  1.0 to 2.0 mm (0.0394 to 0.0787 in.)
  
  If the pedal free play is less than 1.0 mm (0.0394 in.), check the protrusion of the stop light switch shaft.
  
  Protrusion of the stop light switch shaft
  
  1.5 to 2.6 mm (0.0591 to 0.102 in.)
  
  If the protrusion is not within the specified value range, adjust it.
  
  If the protrusion is within the specified value range, troubleshoot the brake system and proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure below.
CHECK BRAKE PEDAL RESERVE DISTANCE
1. Release the parking brake. Start the engine.
2. Depress the brake pedal and check the pedal reserve distance.
  
  Fig 5: Identifying Brake Pedal Reserve Distance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Depress the pedal with a force of 200 N (20 kgf, 45.0 lbf).
  2. Measure the distance between the pedal and No. 2 dash panel insulator pad shown in the illustration.
    Standard pedal reserve distance
    
    More than 95 mm (3.74 in.)
    
    If the distance is not as specified, troubleshoot the brake system.