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Brake Pedal Stroke Sensor: 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 the door courtesy switch turns on. Therefore during servicing of 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 sensor. If the sensor has been dropped replace the sensor with a new one.
    1. When installing a new brake pedal stroke sensor assembly.

      Install a new brake pedal stroke sensor assembly as follows

      NOTE:
      • Do not break the sensor lever set pin before installing the brake pedal stroke sensor with the bolts. If the sensor lever set pin breaks while tightening the bolt, do not use that sensor.
      1. Connect the sensor connector.
      2. Install a new sensor with the 2 bolts.

        Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

        NOTE:
        • Engage the sensor lever with the brake pedal groove.
        • Check that there is no foreign matter attached to the contact surface of the sensor.
        • Check that the tip of the sensor lever is protruding from the brake pedal groove.
          Fig 1: Identifying Brake Pedal Groove With Sensor Lever And Bolts
          G04949805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Firmly depress the brake pedal and break the sensor lever set pin.
      4. Remove the broken lever set pin.
    2. When reusing the brake pedal stroke sensor assembly:

      Install the brake pedal stroke sensor assembly as follows

      1. Connect the sensor connector.
      2. Temporarily install the sensor with the 2 bolts.
        NOTE:
        • Engage the sensor lever with the brake pedal groove.
        • Check that there is no foreign matter attached to the contact surface of the sensor.
          Fig 2: Identifying Brake Pedal Groove With Sensor Lever And Bolts
          G04949806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Connect the cable to the negative battery terminal.
      4. Connect the Intelligent tester or Techstream to the DLC3.
      5. Turn the power switch ON (IG) Reading the value of the stroke sensor shown on the data monitor, turn the sensor slowly to the right and left to adjust the output voltage to the standard voltage.
        Fig 3: Turning Power Switch ON (IG) Of Stroke Sensor
        G04949841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard voltage 

        Intelligent tester 

        VOLTAGE SPECIFICATION

        Tester Display Measurement Item/Range Normal Condition
        PEDAL STROKE Stroke sensor / min.: 0 V, max.: 5 V When brake pedal is released 0.7 to 1.3 V

        Techstream 

        VOLTAGE SPECIFICATION

        Tester Display Measurement Item/Range Normal Condition
        Stroke Sensor Stroke sensor/ min.: 0 V, max.: 5 V When brake pedal is released: 0 7 to 1.3 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. Disconnect the cable from the negative battery terminal.
      8. Disconnect the Intelligent tester or Techstream.
  2. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY  (See INSTALLATION ).
  3. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION ).
  4. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY  (See INSTALLATION ).
  5. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION ).
  6. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY  (See INSTALLATION ).
  7. INSTALL STEERING COLUMN COVER (w/o Driver Monitor Camera)  (See INSTALLATION ).
  8. INSTALL STEERING COLUMN COVER (w/ Driver Monitor Camera)  (See INSTALLATION ).
  9. INSTALL NO. 1 INSTRUMENT CLUSTER MOULDING  (See INSTALLATION ).
  10. INSTALL INSTRUMENT SIDE PANEL LH  (See INSTALLATION ).
  11. INSTALL INSTRUMENT PANEL FINISH PANEL END LH  (See INSTALLATION ).
  12. INSTALL SERVICE PLUG GRIP  (See INSTALLATION ).
  13. INSTALL BATTERY SERVICE HOLE COVER  (See INSTALLATION ).
  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:
    • Reset the AUTO TILT AWAY function setting to the previous condition by changing the customize parameter (see CUSTOMIZE PARAMETERS ).
    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  15. INSTALL BATTERY SERVICE HOLE COVER LH  (See INSTALLATION ).
  16. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY  (See INSTALLATION ).
  17. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (see DIAGNOSIS SYSTEM ).
  18. CHECK AND CLEAR DTC 
    1. Check and clear the DTCs (see DTC CHECK / CLEAR  ).
  19. PERFORM LINEAR VALVE OFFSET LEARNING 
    1. Perform the linear valve offset learning (see INITIALIZATION  ).
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