Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION





1. CHECK PEDAL HEIGHT
Pedal height from floor panel: 133.8 - 143.8 mm (5.268 - 5.661 inch)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
a. Remove the under cover, lower pad and air duct.
b. Disconnect the connector from the stop light switch.
c. Loosen the stop light switch lock nut and remove the stop light switch.
d. Loosen the push rod lock nut.
e. Adjust the pedal height by turning the pedal push rod.
f. Tighten the push rod lock nut.
Torque: 25 Nm (260 kgf.cm, 19 ft. lbs.)
g. Install the stop light switch.
h. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), turn the stop light switch to lock the nut in the position where the stop light goes off.
i. Connect the connector to the stop light switch.
j. After installation, push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), check that stop light lights up.
k. After adjusting the pedal height, check the pedal freeplay.





3. CHECK PEDAL FREEPLAY
a. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
b. Push in the pedal by hand until the beginning of the second point of resistance is felt, then measure the distance, as shown.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 inch)
If the clearance incorrect, check the stop light switch clearance. If it is OK, then troubleshoot the brake system.

HINT: The freeplay to the 1st point of resistance is due to the play between the clevis and pin. It is 1 - 3 mm (0.04 - 0.12 in.) on the pedal.

c. Install the air duct, lower pad and under cover.





4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake.
With the engine running, depress the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance at 490 N (50 kgf, 110.2 lbs.): More than 70 mm (2.76 inch)
If the reserve distance is incorrect, troubleshoot the brake system.