BRAKE PEDAL STROKE SENSOR INSTALLATION

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. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

    1. Check the brake pedal height.

      1. Turn back the carpet.

      2. Turn back the dash panel insulator assembly from the slit provided on the dash panel insulator assembly.

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

        A011Y8SE01
        Text in Illustration
        *1 Stop Light Switch Assembly
        *2 Floor Panel
        *a Brake Pedal Height
        Pedal height from floor panel
        138.5 to 148.5 mm (5.46 to 5.84 in.)

        If pedal height is incorrect, inspect and adjust the push rod length according to the procedure below.

    2. Adjust the push rod length.

      1. Remove the stop light switch assembly Click here.

      2. Remove the brake booster with master cylinder assembly Click here.

      3. Loosen the lock nut and adjust the push rod length shown in the illustration by turning the brake master cylinder push rod clevis to achieve the correct length.

        A011Y7ME01
        Text in Illustration
        *1 Lock Nut
        *2 Brake Master Cylinder Push Rod Clevis
        *a Push Rod Length
        Push rod length
        115.5 to 116.5 mm (4.55 to 4.58 in.)

      4. Tighten the lock nut.

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

      5. Install the brake booster with master cylinder assembly Click here.

        • If the pedal height is incorrect even when the push rod length is adjusted, check the brake pedal support assembly and floor panel.

        • If necessary, replace the brake pedal support assembly.

      6. Install the stop light switch assembly Click here.

    3. After adjusting the pedal height, check the brake pedal free play.

  2. 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 bolt.

      1. Install a new brake pedal stroke sensor assembly to the brake pedal support assembly with the 2 bolts.

        A011W6ME01
        Text in Illustration
        *1 Brake Pedal Stroke Sensor Assembly Lever
        *a Brake Pedal Groove
        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

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

      3. Remove the broken lever set pin.

      4. Connect the connector to the brake pedal stroke sensor assembly.

    2. When reusing the brake pedal stroke sensor assembly:

      1. Temporarily install the brake pedal stroke sensor assembly to the brake pedal support assembly with the 2 bolts.

        A011W6ME01
        Text in Illustration
        *1 Brake Pedal Stroke Sensor Assembly Lever
        *a Brake Pedal Groove

        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.

        Tech Tips

        Fully tighten the 2 bolts when adjusting the brake pedal stroke sensor assembly.

      2. Connect the connector to the brake pedal stroke sensor assembly.

  3. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Click here

  4. ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY

    Note

    When the brake pedal stroke sensor assembly is being reused, perform the following procedure to adjust it.

    1. Connect the Techstream to the DLC3.

    2. Turn the power switch on (IG).

    3. Turn the Techstream on.

    4. Enter the following menus: Chassis / ABS/VSC/TRAC / Data List "Stroke Sensor".

    5. Read the stroke sensor value in the Data List, and turn the brake pedal stroke sensor assembly slowly to the right or left to adjust the output voltage so that it is within the following range.

      A011VSO
      Standard voltage (without the brake pedal depressed)
      0.8 to 1.2 V

    6. Tighten the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

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

    7. Turn the Techstream off.

    8. Turn the power switch off.

    9. Disconnect the Techstream.

  5. CHECK AND CLEAR DTC

    Click here

  6. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE

    Click here