Brake Pedal Assy: Adjustments

BRAKE: BRAKE PEDAL: ADJUSTMENT

1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

(a) Check the brake pedal height.





Pedal height from No. 3 dash panel insulator pad (for 2WD):

120.5 to 130.5 mm (4.744 to 5.138 in.)

Pedal height from No. 3 dash panel insulator pad (for 4WD):

117.1 to 127.1mm (4.610 to 5.004 in.)

(b) Adjust brake pedal height.

(1) Disconnect the connector from the stop light switch assembly.

(2) Remove the stop light switch lock nut. Turn the switch in order to give the pedal some free play.

(3) for 2GR-FSE:

Remove the brake booster assembly.

(4) for 1UR-FSE:

Remove brake master cylinder with simulator assembly.

(5) for 2GR-FSE:

Loosen the push rod lock nut, turn the push rod clevis and adjust length "A" shown in the illustration.

Length "A":

146.2 to 147.2 mm (5.756 to 5.795 in.)





(6) for 1UR-FSE:

Loosen the push rod lock nut, turn the push rod clevis and adjust length "A" shown in the illustration.

Length "A":

147.5 to 148.5 mm (5.807 to 5.846 in.)





(7) Tighten the push rod lock nut.

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

(8) for 2GR-FSE:

Install the brake booster assembly.

(9) for 1UR-FSE:

Install brake master cylinder with simulator assembly.

(10) Turn the stop light switch assembly so that the clearance between its and the area where the pedal makes contact is between 0.5 and 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.





Torque : 17 Nm (170 kgf-cm, 12 ft-lbf)

(11) Connect the connector to the stop light switch assembly.

(c) Adjust the brake pedal stroke sensor.

(1) Connect the Techstream to the DLC3.

(2) Loosen the 2 nuts.

(3) Turn the engine switch on (IG). Reading the stroke sensor 1 value shown on the data monitor, 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

NOTICE:
Do not depress the brake pedal after turning the engine switch on (IG).

(4) Tighten the 2 nuts.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(d) Perform system initialization. Initialization

2. INSPECT PEDAL FREE PLAY

(a) Stop the engine and depress the brake pedal several times until no vacuum is left in the booster.

(b) Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.





Pedal free play:

1.0 to 2.0 mm (0.039 to 0.079 in.)

If the pedal free play is 1 mm (0.04 in) or less, check the protrusion of the stop light switch assembly shaft.

Protrusion of the stop light switch assembly shaft:

0.5 to 2.4 mm (0.020 to 0.095 in.)

If the protrusion is off the specified value, adjust it.

If the protrusion is within the specified value, it is normal though brake pedal free play is 1.0 mm (0.039 in.) or less.

3. INSPECT PEDAL RESERVE DISTANCE

(a) Release the parking brake pedal.





Text in Illustration





(b) With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.

Pedal reserve distance from No. 3 dash panel insulator pad at 500 N (51 kgf, 112 lbf) for 2GR-FSE:

More than 65 mm (2.56 in.)

Pedal reserve distance from No. 3 dash panel insulator pad at 200 N (20 kgf, 45 lbf) for 1UR-FSE:

More than 74 mm (2.91 in.)

If incorrect, troubleshoot the brake system. Vehicle Stability Control System (w/o VDIM)