Brake Pedal Support: Adjustment

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

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.
  Standard pedal height from tibia pad:
  
  144.2 to 154.2 mm (5.68 to 6.07 in.)
  
  Fig 1: Identifying Push Rod Clevis Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 tibia pad:
    
    144.2 to 154.2 mm (5.68 to 6.07 in.)
  5. Tighten the push rod clevis lock nut.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  6. Turn the stop light switch so that its protrusion is between 1.5 and 2.6 mm (0.0591 and 0.102 in.). Then tighten the lock nut.
    Torque: 17 N*m (170 kgf*cm, 12 ft.*lbf)
    
    Fig 2: Identifying Stop Light Switch Lock Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 (0 197 to 0.394 in), and check that the stop light illuminates.
    If the stop light does not illuminate, adjust the brake pedal height again
ADJUST BRAKE PEDAL STROKE SENSOR
1. Connect the intelligent tester or Techstream to the DLC3 with the power switch OFF
2. Loosen the 2 bolts
3. Turn the power switch ON (IG). While reading the stroke sensor 1 value shown on the intelligent tester or 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 N*m (87 kgf*cm, 75 in.*lbf)
5. Perform the linear valve offset learning (see INITIALIZATION )
  NOTE: Do not depress the brake pedal while performing the linear valve offset learning, as this may cause a DTC to be stored.
CHECK BRAKE PEDAL FREE PLAY
1. Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration
  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.
  
  Fig 4: Checking Brake Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK BRAKE PEDAL RESERVE DISTANCE
1. Release the parking brake. Start the engine.
2. Depress the brake pedal and check the pedal reserve distance.
  1. Depress the pedal with a force of 200 N (20 kgf, 45.0 lbf).
  2. Measure the distance between the pedal and tibia 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.