Brake Pedal Support ASSY: Adjustment

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Check brake pedal height.
  Pedal height from asphalt sheet: 144.1 to 154.1 mm (5.673 to 6.067 in.)
  
  Fig 1: Checking & Adjusting Brake Pedal Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Adjust brake pedal height.
  1. Remove the instrument panel finish panel sub assy lower and instrument panel insert sub-assy lower LH.
  2. Disconnect the connector from the stop lamp switch assy.
  3. Loosen the stop lamp switch lock nut and remove the stop lamp switch assy.
  4. Loosen the push rod lock nut.
  5. Adjust the pedal height by turning the pedal push rod.
  6. Tighten the push rod lock nut.
    Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
  7. Install the stop lamp switch assy.
  8. Connect the connector to the stop lamp switch assy.
  9. Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.) and turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off.
  10. After installation, push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that stop lamp comes on.
  11. Tighten the stop lamp switch lock nut.
    Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
  12. Install the instrument panel insert sub-assy lower LH and instrument panel finish panel sub-assy lower.
CHECK PEDAL FREE PLAY
1. Stop the engine and depress the brake pedal several times until no vacuum remains in the booster.
2. Press the pedal until resistance is felt. Measure the distance, as shown inFig 2 .
  Pedal free play: 1 to 6 mm (0.04 to 0.24 in.)
  
  If incorrect, proceed to the following step.
  1. Check the stop lamp switch clearance.
    Stop lamp switch clearance: 0.5 to 2.4 mm (0.020 to 0.095 in.)
  If correct, the pedal free play is OK.
  
  If incorrect, adjust the stop lamp switch clearance.
  
  Fig 2: Checking Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PEDAL RESERVE DISTANCE
1. Release the parking brake lever.
  With the engine running, depress the pedal and measure the pedal reserve distance, as shown inFig 3 .
  
  Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbf):
  - w/o VSC: More than 68.5 mm (2.7 in.)
  - w/ VSC: More than 78.0 mm (3.1 in.)
If incorrect, troubleshoot the brake system.

Fig 3: Depressing Pedal & Measuring Pedal Reserve Distance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002