Toyota Prius: Brake Pedal Stroke Sensor

• Removal
• Installation

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 the brake pedal stroke sensor 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	Link
Brake pedal stroke sensor assembly	Perform "Calibration"	DTCs are stored ABS warning light illuminates Brake system warning light (yellow indicator) illuminates Slip indicator light illuminates Electronically controlled brake system disabled or malfunctions

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when Toyota Prius vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
*1: w/o Power Back Door System *2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	for HEV Model: After the ignition switch is turned to ON, the servo motor standard position is recognized. for PHEV Model: After the ignition switch is turned to ON, the servo motor and expansion valve standard position is recognized.	-

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	PRECAUTION	-		-	-
2	CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
3	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
4	BRAKE PEDAL STROKE SENSOR ASSEMBLY	89510D		-	-

PROCEDURE

1. PRECAUTION

NOTICE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Click here

2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

for M20A-FXS: Click here

for 2ZR-FXE: Click here

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

Click here

4. REMOVE BRAKE PEDAL STROKE SENSOR ASSEMBLY

(1) Disconnect the connector from the brake pedal stroke sensor assembly.

(2) Remove the 2 nuts and brake pedal stroke sensor assembly from the brake pedal support assembly.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	INSPECT AND ADJUST BRAKE PEDAL HEIGHT	-		-	-
2	INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY	89510D		-	-
3	CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL	-		-	-
4	ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY	89510D		-	-
5	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
6	PERFORM INITIALIZATION AND CALIBRATION	-	-
7	CHECK AND CLEAR DTC	-	-	-
8	INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL	-	-	-

Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

-

-

PROCEDURE

1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

Click here

2. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY

(a) When installing a new brake pedal stroke sensor assembly:

*a	Brake Pedal Stroke Sensor Assembly Lever	*b	Brake Pedal Groove
*c	Brake Pedal Stroke Sensor Assembly Lever Set Pin	-	-

(1) Install a new brake pedal stroke sensor assembly to the brake pedal support assembly with the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(2) Connect the connector.

(3) Firmly depress the brake pedal to break the brake pedal stroke sensor assembly lever set pin.

(4) Remove the broken lever set pin.

(b) When reusing the brake pedal stroke sensor assembly:

*a

Brake Pedal Stroke Sensor Assembly Lever

*b

Brake Pedal Groove

(1) Install the brake pedal stroke sensor assembly to the brake pedal support assembly and temporarily tighten the 2 nuts.

(2) Connect the connector.

3. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for M20A-FXS: Click here

for 2ZR-FXE: Click here

4. ADJUST BRAKE PEDAL STROKE SENSOR ASSEMBLY

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

(1) 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.

Chassis > Brake Booster > Data List

Tester Display
Stroke Sensor

Standard Voltage (without the brake pedal depressed):

0.8 to 1.2 V

(2) Tighten the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

NOTICE:

After turning the ignition switch to ON, do not depress the brake pedal until the nuts have been tightened.

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

Click here

6. PERFORM INITIALIZATION AND CALIBRATION

Click here

7. CHECK AND CLEAR DTC

Click here

8. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click here