Toyota Avalon (XX50): Brake Pedal(for Gasoline Model)

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Brake / Brake System (other) / Brake Pedal(for Gasoline Model)

Adjustment

ADJUSTMENT

PROCEDURE

1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

(a) Remove the front door scuff plate LH.

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(b) Remove the cowl side trim sub-assembly LH.

Click here

(d) Remove the accelerator pedal pad.

Click here

(e) Remove the accelerator pedal.

Click here

(f) Check the brake pedal height.

HINT:

Inspect and adjust the brake pedal height with the floor carpet and front floor mat folded back.

(1) Measure the shortest distance between the brake pedal pad surface and floor panel as shown in the illustration.

*1	Brake Pedal Pad	-	-
*a	Brake Pedal Height	*b	Measuring Plane of Floor Panel
*c	36 mm (1.42 in.)	-	-

Brake Pedal Height from Floor Panel:

147.5 to 161.5 mm (5.81 to 6.36 in.)

HINT:

If the brake pedal height is not as specified, inspect and adjust the push rod length according to the procedure below.

(g) Adjust the push rod length.

(1) Remove the stop light switch assembly.

Click here

*1	Lock Nut
*2	Stop Light Switch Assembly
*a	Floor Panel
*b	Brake Pedal Height

(2) Loosen the lock nut.

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

Brake Pedal Height from Floor Panel:

147.5 to 161.5 mm (5.81 to 6.36 in.)

(4) Tighten the lock nut.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(5) Install the stop light switch assembly.

Click here

(h) Install the accelerator pedal.

Click here

(i) Install the accelerator pedal pad.

Click here

(j) Install the No. 1 instrument panel under cover sub-assembly.

Click here

(k) Install the cowl side trim sub-assembly LH.

Click here

(l) Install the front door scuff plate LH.

Click here

2. INSPECT BRAKE PEDAL FREE PLAY

(a) Stop the engine and firmly depress the brake pedal several times until no vacuum is left in the brake booster assembly.

(b) Depress the brake pedal until a slight resistance is felt. Measure the distance as shown in the illustration.

Brake Pedal Free Play:

1.0 to 6.0 mm (0.0394 to 0.236 in.)

HINT:

If the brake pedal free play is not as specified, check the stop light switch clearance.
Click here
If the brake pedal free play is as specified, proceed to the Inspect Brake Pedal Reserve Distance procedure.

*a	Brake Pedal Free Play

3. INSPECT BRAKE PEDAL RESERVE DISTANCE

HINT:

Measure the distance at the same point used for the brake pedal height inspection.

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

*1	Brake Pedal Pad	-	-
*a	Brake Pedal Reserve Distance	*b	Measuring Plane of Floor Panel
*c	36 mm (1.42 in.)	-	-

Brake Pedal Reserve Distance from Floor Panel at 300 N (31 kgf, 67.4 lbf):

81 mm (3.19 in.) or more

HINT:

If the distance is not as specified, troubleshoot the brake system.

Click here

Components

COMPONENTS

ILLUSTRATION

*1	BRAKE LINE	*2	BRAKE MASTER CYLINDER SUB-ASSEMBLY
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : Nm (kgfcm, ft.*lbf)	*	For use with a union nut wrench

ILLUSTRATION

NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

ILLUSTRATION

*A	w/ Rubber Pad	*B	w/ Aluminum Pad
*1	BRAKE PEDAL PAD	*2	BRAKE PEDAL RETURN SPRING
*3	BRAKE PEDAL SUPPORT ASSEMBLY	*4	PUSH ROD PIN
*5	STOP LIGHT SWITCH ASSEMBLY	*6	STOP LIGHT SWITCH MOUNTING ADJUSTER
*7	BRAKE MASTER CYLINDER PUSH ROD CLEVIS	*8	LOCK NUT
*9	WIRE HARNESS	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : Nm (kgfcm, ft.*lbf)	●	Non-reusable part
	Lithium soap base glycol grease	-	-

Installation

INSTALLATION

PROCEDURE

1. INSTALL BRAKE PEDAL PAD

(a) Install the brake pedal pad to the brake pedal support assembly.

HINT:

Installation is easier after applying a small amount of soapy water.

2. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER

(a) Engage the 2 claws to install the stop light switch mounting adjuster.

3. INSTALL BRAKE PEDAL RETURN SPRING

(a) Install the brake pedal return spring to the brake pedal support assembly.

NOTICE:

Attach the bottom part of the brake pedal return spring first, making sure that the open part of the hook is facing the front of the vehicle. Attach the top part of the brake pedal return spring second, making sure that the open part of the hook is facing the rear of the vehicle.

4. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY

(a) Push the brake booster assembly toward the engine compartment, and install the brake pedal support assembly while avoiding the stud bolts of the brake booster assembly and brake booster support base.

NOTICE:

Be careful not to deform the bracket of the instrument panel reinforcement assembly.
Do not apply excessive force to the brake lines.
Do not apply excessive force to the wire harness.

(b) Return the brake booster assembly to its original position.

Torque:

12.8 N·m {131 kgf·cm, 9 ft·lbf}

(d) Install the brake pedal support assembly to the instrument panel reinforcement assembly with the bolt.

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

(e) Engage the clamp to install the wire harness to the brake pedal support assembly.

5. INSTALL PUSH ROD PIN

(a) Apply lithium soap base glycol grease to the push rod pin.

Lithium Soap Base Glycol Grease

(b) Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the push rod pin, and install a new clip as shown in the illustration.

HINT:

The push rod pin can be installed in either direction.

6. INSTALL STOP LIGHT SWITCH ASSEMBLY

Click here

7. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

8. CONNECT BRAKE LINE

(a) Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.

Torque:

Specified tightening torque :

19.5 N·m {199 kgf·cm, 14 ft·lbf}

NOTICE:

Do not kink or damage the brake lines.
Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
17.4 N*m (177 kgf*cm, 13 ft.*lbf)

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

9. BLEED BRAKE SYSTEM

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10. INSTALL BATTERY

Click here

11. INSPECT AND ADJUST BRAKE PEDAL

Click here

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during brake pedal support assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane departure alert system (w/ Steering Control)
		Pre-collision system
		Intelligent Clearance Sonar System*
		Lighting System (for Gasoline Model with Cornering Light)
	Memorize steering angle neutral point	Parking assist monitor system
	Memorize steering angle neutral point	Panoramic View Monitor System

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Click here

2. REMOVE BATTERY

Click here

3. DRAIN BRAKE FLUID

NOTICE:

If brake fluid leaks onto any painted surface, immediately wash it off.

4. DISCONNECT BRAKE LINE

(a) Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

NOTICE:

Do not damage or deform the brake lines.
Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

5. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

6. REMOVE STOP LIGHT SWITCH ASSEMBLY

Click here

7. REMOVE PUSH ROD PIN

(a) Remove the clip and push rod pin.

8. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY

(a) Disengage the clamp to separate the wire harness from the brake pedal support assembly.

(b) Remove the bolt and separate the brake pedal support assembly from the instrument panel reinforcement assembly.

	Nut
	Clip

HINT:

Depending on the vehicle, the clips may not be installed.

(d) Remove the 4 nuts and push the brake booster assembly toward the engine compartment.

NOTICE:

Do not apply excessive force to the brake lines.
Do not apply excessive force to the wire harness.

(e) Remove the brake pedal support assembly while avoiding the stud bolts of the brake booster assembly and brake booster support base.

NOTICE:

Be careful not to deform the bracket of the instrument panel reinforcement assembly.

9. REMOVE BRAKE PEDAL RETURN SPRING

(a) Remove the brake pedal return spring from the brake pedal support assembly.

10. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER

(a) Disengage the 2 claws and remove the stop light switch mounting adjuster.

11. REMOVE BRAKE PEDAL PAD

(a) Remove the brake pedal pad from the brake pedal support assembly.

Brake Master Cylinder(for Gasoline Model)

Brake Pedal(for Hv Model)

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