INSPECT AND ADJUST BRAKE PEDAL HEIGHT

INSPECT PEDAL FREE PLAY

INSPECT PEDAL RESERVE DISTANCE

Check the brake pedal height.

• Pedal height from asphalt sheet (AT for LHD):
• 151.8 to 161.8 mm (5.976 to 6.370 in.)

• Pedal height from asphalt sheet (AT for RHD):
• 147.0 to 157.0 mm (5.787 to 6.181 in.)

• Pedal height from asphalt sheet (MT for LHD):
• 146.6 to 156.6 mm (5.772 to 6.165 in.)

• Pedal height from asphalt sheet (MT for RHD):
• 154.0 to 164.0 mm (6.063 to 6.457 in.)

Adjust brake pedal height.

Disconnect the connector from the stop light switch assembly.

Loosen the stop light switch lock nut. Turn the switch in order to give the pedal some free play.

Remove the brake booster assembly.

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

• Dimension "A":
• 146.2 to 147.2 mm (5.756 to 5.795 in.)

Tighten the push rod lock nut.

• Torque:
• 26 N*m{ 265 kgf*cm, 19 ft.*lbf}

Install the brake booster assembly.

Turn the stop light switch assembly so that the clearance between the switch 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 N*m{ 170 kgf*cm, 12 ft.*lbf}

Connect the connector to the stop light switch assembly.

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

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 1.0 mm (0.039 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 not within the specified range, adjust it.

If the protrusion of the stop light switch is within the specified range, and the brake pedal free play is 1.0 mm (0.039 in.) or less, the brake pedal free play can be considered acceptable.

Release the parking brake pedal.

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

• Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbf):
• 4GR-FSE, AT, for LHD:
• More than 108 mm (4.25 in.)
• 4GR-FSE, AT, for RHD:
• More than 104 mm (4.09 in.)
• 4GR-FSE, MT, for LHD:
• More than 104 mm (4.09 in.)
• 4GR-FSE, MT, for RHD:
• More than 110 mm (4.33 in.)
• 2AD-FHV, MT, for LHD:
• More than 103 mm (4.06 in.)
• 2AD-FHV, MT, for RHD:
• More than 108 mm (4.25 in.)

If incorrect, troubleshoot the brake system.