Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001XSY8
Model Year Start: 2022 Model: Avalon HV Prod Date Range: [08/2021 -           ]
Title: BRAKE SYSTEM (OTHER): BRAKE PEDAL (for HV Model): ADJUSTMENT; 2022 MY Avalon HV [08/2021 -        ]

ADJUSTMENT

PROCEDURE

1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

(a) Remove the front door scuff plate LH.

Click here 2022 MY Avalon Avalon HV [08/2021 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

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

Click here 2022 MY Avalon Avalon HV [08/2021 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

(c) Remove the No. 1 instrument panel under cover sub-assembly.

Click here 2022 MY Avalon Avalon HV [08/2021 -        ]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: REMOVAL+

(d) Remove the accelerator pedal pad.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: ACCELERATOR PEDAL SENSOR: REMOVAL+

(e) Remove the accelerator pedal.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: ACCELERATOR PEDAL SENSOR: REMOVAL+

(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

41 mm (1.61 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 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; LIGHTING (EXT): STOP LIGHT SWITCH: REMOVAL

*1

Stop Light Switch Assembly

*2

Lock Nut

*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:

25.5 N·m {260 kgf·cm, 19 ft·lbf}

(5) Install the stop light switch assembly.

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; LIGHTING (EXT): STOP LIGHT SWITCH: INSTALLATION

(h) Install the accelerator pedal.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: ACCELERATOR PEDAL SENSOR: INSTALLATION+

(i) Install the accelerator pedal pad.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: ACCELERATOR PEDAL SENSOR: INSTALLATION+

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

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: INSTALLATION+

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

Click here 2021 - 2022 MY Avalon Avalon HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: INSTALLATION+

(l) Install the front door scuff plate LH.

Click here 2021 - 2022 MY Avalon Avalon HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: INSTALLATION+

2. INSPECT AND ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY

(a) Inspect the brake pedal stroke sensor assembly.

(1) Connect the Techstream to the DLC3 with the power switch off.

(2) Turn the power switch on (IG).

(3) Turn the Techstream on and enter the following menus: Chassis / ABS/VSC/TRAC / Data List / Stroke Sensor.

Chassis > ABS/VSC/TRAC > Data List

Tester Display

Stroke Sensor

(4) Read the stroke sensor value without the brake pedal depressed.

Standard Voltage (without the brake pedal depressed):

0.8 to 1.2 V

HINT:

If the stroke sensor value is not within the standard voltage, adjust the brake pedal stroke sensor assembly.

(b) Adjust the brake pedal stroke sensor assembly.

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

Click here 2022 MY Avalon Avalon HV [08/2021 -        ]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: REMOVAL+

(2) Loosen the 2 nuts.

NOTICE:

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

(3) 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.

Standard Voltage (without the brake pedal depressed):

0.8 to 1.2 V

(4) Tighten the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(5) Turn the Techstream off and turn the power switch off.

(6) Disconnect the Techstream.

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

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: INSTALLATION+

(c) Perform linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization.

Click here 2022 MY Avalon HV [08/2021 -        ]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): INITIALIZATION

3. INSPECT BRAKE PEDAL FREE PLAY

(a) 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 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; LIGHTING (EXT): STOP LIGHT SWITCH: INSTALLATION+

  • If the brake pedal free play is as specified, proceed to the Inspect Brake Pedal Reserve Distance procedure.

*a

Brake Pedal Free Play

4. INSPECT BRAKE PEDAL RESERVE DISTANCE

HINT:

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

(a) With the power switch on (READY), depress the brake pedal and measure the brake pedal reserve distance.

*1

Brake Pedal Pad

-

-

*a

Brake Pedal Reserve Distance

*b

Measuring Plane of Floor Panel

*c

41 mm (1.61 in.)

-

-

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

85 mm (3.35 in.) or more

HINT:

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

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; BRAKE SYSTEM (OTHER): BRAKE SYSTEM (for HV Model): PROBLEM SYMPTOMS TABLE