Toyota Camry
XV30 (2002–2006) Service Manual
Brake
Accelerator & brake pedal assy

ADJUSTMENT

1. CHECK AND ADJUST BRAKE PEDAL HEIGHT

Inspect brake pedal height.

Pedal height from asphalt sheet:
144.1 − 154.1 mm (5.673 − 6.067 in.)
Adjust brake pedal height.

Remove the instrument panel finish panel sub− assy lower and instrument panel insert sub−assy lower LH.
Disconnect the connector from the stop lamp switch assy.
Loosen the stop lamp switch lock nut and remove the stop lamp switch assy.
Loosen the clevis lock nut.
Adjust the pedal height by turning the pedal push rod.
Tighten the push rod lock nut.

Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)
Install the stop lamp switch assy.
Connect the connector to the stop lamp switch assy.
Push the brake pedal in 5 − 10 mm (0.20 − 0.39 in.), turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off.
After installation, push the brake pedal in 5 − 10 mm (0.20 − 0.39 in.), check that stop lamp lights up.(11) Install the instrument panel insert sub−assy lower LH and instrument panel finish panel sub−assy lower.

Check and adjust brake pedal height

2. CHECK PEDAL FREE PLAY

Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown.

Pedal free play: 1 − 6 mm (0.04 − 0.24 in.)

If incorrect, check the stop lamp switch assy clearance.

If the clearance is OK, then troubleshoot the brake system.

Stop lamp switch clearance: 0.5 − 2.5 mm (0.020 − 0.098 in.)

Check pedal free play

3. CHECK PEDAL RESERVE DISTANCE

Release the parking brake pedal.

With engine running, depress the pedal and measure the pedal reserve distance, as shown.

Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 63 mm (2.48 in.)

If incorrect, troubleshoot the brake system.

Check pedal reserve distance

COMPONENTS

OVERHAUL

OVERHAUL

PRECAUTION
DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE STEERING WHEEL COVER LOWER No.2
REMOVE STEERING WHEEL COVER LOWER No.2 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)
REMOVE POWER WINDOW LOCK SWITCH BULB (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)
REMOVE STEERING WHEEL COVER LOWER No.3 (3 SPOKE STEERING WHEEL ASSY)
INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD
REMOVE HORN BUTTON ASSY
REMOVE STEERING WHEEL ASSY
SST 09950−50013 (09951−05010, 09952−05010, 09953−05020, 09954−05021)
REMOVE INSTRUMENT CLUSTER FINISH PANEL
REMOVE STEERING COLUMN COVER
DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY
REMOVE FRONT DOOR SCUFF PLATE LH
REMOVE COWL SIDE TRIM SUB−ASSY LH
REMOVE INSTRUMENT PANEL COIN BOX SUB−ASSY
REMOVE INSTRUMENT PANEL SUB−ASSY UPPER
REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH
REMOVE DUCT, FR VENTILATOR, LH
DISCONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY
REMOVE STEERING COLUMN ASSY
REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSY

Remove the 3 nuts and junction block assy, then disconnect the connector.

Remove instrument panel junction block assy

22. REMOVE BRAKE PEDAL RETURN SPRING

Remove brake pedal return spring

23. REMOVE PUSH ROD PIN

Remove the clip and push rod pin.

Remove push rod pin

24. REMOVE ACCELERATOR & BRAKE PEDAL ASSY

Disconnect the stop lamp switch connector.

Disconnect the accel position connector.

Remove the 4 bolts, 4 nuts and accelerator & brake pedal assy.

25. REMOVE STOP LAMP SWITCH ASSY

25. REMOVE STOP LAMP SWITCH ASSY

Loosen the nut and remove the stop lamp switch assy.

Remove stop lamp switch assy

REMOVE BRAKE PEDAL PAD
REMOVE STOP LAMP SWITCH CUSHION

Remove stop lamp switch cushion

28. REMOVE ACCELERATOR PEDAL ASSY

Remove the bolt, nut and accelerator pedal assy.

Remove accelerator pedal assy

29. INSTALL ACCELERATOR PEDAL ASSY

Install the accelerator pedal assy with nut and bolt.

Torque: 12 N·m (122 kgf·cm, 8.8 ft·lbf)

Install accelerator pedal assy

30. INSTALL STOP LAMP SWITCH CUSHION

Install stop lamp switch cushion

INSTALL BRAKE PEDAL PAD
INSTALL STOP LAMP SWITCH ASSY

Install the stop lamp switch assy with a nut.

Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)

Install stop lamp switch assy

33. INSTALL ACCELERATOR & BRAKE PEDAL ASSY

Install the accelerator & brake pedal assy with the 4 nuts and 4 bolts.

Torque:
Nut: 13 N·m (130 kgf·cm, 9 ft·lbf) Bolt: 19.1 N·m (194 kgf·cm, 14 ft·lbf)

Connect the accel position connector.

Connect the stop lamp switch connector.

34. INSTALL PUSH ROD PIN

34. INSTALL PUSH ROD PIN

Install the push rod pin and clip.

HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows

Install push rod pin

35. INSTALL BRAKE PEDAL RETURN SPRING

Install brake pedal return spring

36. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY

Install the junction block assy with the 3 nuts, then connect the each connector.

Install instrument panel junction block assy

INSTALL STEERING COLUMN ASSY
CONNECT STEERING INTERMEDIATE SHAFT SUB−ASSY
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY
CHECK KEY INTERLOCK OPERATION
INSTALL STEERING COLUMN COVER
INSTALL INSTRUMENT CLUSTER FINISH PANEL
INSTALL DUCT, FR VENTILATOR, LH
INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH
INSTALL INSTRUMENT PANEL SUB−ASSY UPPER
INSTALL INSTRUMENT PANEL COIN BOX SUB−ASSY
INSTALL COWL SIDE TRIM SUB−ASSY LH
INSTALL FRONT DOOR SCUFF PLATE LH
CENTER SPIRAL CABLE
INSTALL STEERING WHEEL ASSY
INSPECT HORN BUTTON ASSY
INSTALL HORN BUTTON ASSY
INSTALL STEERING WHEEL COVER LOWER No.2
INSTALL STEERING WHEEL COVER LOWER No.3 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)
INSTALL POWER WINDOW LOCK SWITCH BULB (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL)
INSTALL STEERING WHEEL COVER LOWER No.3 (3 SPOKE STEERING WHEEL ASSY)
INSPECT STEERING WHEEL CENTER POINT
INSPECT SRS WARNING LI