BRAKE PEDAL STROKE SENSOR (for LHD) INSTALLATION

Note

While the battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the battery is connected.


  1. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY

    Note

    Do not drop the brake pedal stroke sensor assembly. If the brake pedal stroke sensor assembly has been dropped, replace the brake pedal stroke sensor assembly with a new one.


    1. When installing a new brake pedal stroke sensor assembly:

      Note

      Do not break the brake pedal stroke sensor assembly lever set pin before installing the brake pedal stroke sensor assembly with the nuts.


      1. A01JD8NE02
        Text in Illustration
        *1 Brake Pedal Groove
        *2 Brake Pedal Stroke Sensor Assembly Lever

        Temporarily install a new brake pedal stroke sensor assembly with the 2 nuts.

        Note


        • Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.

        • Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor assembly.

        • Check that the tip of the brake pedal stroke sensor assembly lever is protruding from the brake pedal groove.

    2. When reusing the brake pedal stroke sensor assembly:


      1. A01JD8NE02
        Text in Illustration
        *1 Brake Pedal Groove
        *2 Brake Pedal Stroke Sensor Assembly Lever

        Temporarily install the brake pedal stroke sensor assembly with the 2 nuts.

        Note


        • Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.

        • Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor assembly.

        • Check that the tip of the brake pedal stroke sensor assembly lever is protruding from the brake pedal groove.

  2. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY

    Tech Tips

    Refer to the instructions for installation of the Brake Pedal Support Assembly Click here.

  3. INSPECT AND ADJUST BRAKE PEDAL


    1. Check the brake pedal height.


      1. Turn back the carpet.

      2. Turn back the dash silencer from the slit provided on the dash silencer.

      3. A01JAOJE01
        Text in Illustration
        *1 Stop Light Switch Assembly
        *2 Clevis Lock Nut
        *3 Floor Panel
        *4 Brake Pedal Height

        Measure the shortest distance between the brake pedal surface and floor panel.

        Brake pedal height from floor panel
        127.7 to 137.7 mm (5.03 to 5.42 in.)

    2. Adjust the brake pedal height.


      1. Remove the stop light switch assembly Click here.

      2. Loosen the clevis lock nut.

      3. Adjust the brake pedal height by turning the push rod.

      4. Tighten the clevis lock nut.

        Torque:
        26 N*m  { 260 kgf*cm, 19 ft.*lbf }

      5. Install and adjust the stop light switch assembly Click here.

  4. ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY


    1. When installing a new brake pedal stroke sensor assembly:


      1. A01JBT8E01

        Fully tighten a new brake pedal stroke sensor assembly with the 2 nuts.

        Torque:
        7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

        Note

        Tighten the 2 nuts in the order shown in the illustration.

      2. Firmly depress the brake pedal and break the brake pedal stroke sensor assembly lever set pin.

      3. Remove the broken lever set pin.

    2. When reusing the brake pedal stroke sensor assembly:


      1. Connect the cable to the negative (-) battery terminal.

      2. Connect the intelligent tester to the DLC3.

      3. Turn the power switch on (IG).

      4. Turn the intelligent tester on.

      5. Enter the following menus: Chassis / ABS/VSC/ TRC / Data List.

      6. A01J9P4

        Reading the value of the brake pedal stroke sensor assembly shown in the Data List, turn the brake pedal stroke sensor assembly slowly to the right and left to adjust the output voltage to the standard voltage.

        Standard Voltage
        Tester Display Measurement Item/Range Normal Condition Diagnostic Note
        Stroke Sensor

        Stroke sensor /

        min.: 0 V, max.: 5 V

        		 0.8 to 1.2 V -

      7. Tighten the 2 nuts.

        Torque:
        7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

        Note


        • Do not depress the brake pedal after turning the power switch on (IG).

        • Tighten the 2 nuts in the order shown in the illustration.

      8. Turn the power switch off.

      9. Disconnect the intelligent tester.

  5. CHECK AND CLEAR DTC


    1. Check and clear the DTCs Click here.

  6. PERFORM LINEAR VALVE OFFSET LEARNING


    1. Perform linear valve offset learning Click here.