Brake Pedal Assy: Testing and Inspection
BRAKE PEDAL SUPPORT SUB-ASSEMBLYON-VEHICLE INSPECTION
1. REMOVE SEAT BELT ANCHOR COVER CAP LH
2. REMOVE SEAT TRACK COVER RH
3. REMOVE SEAT TRACK COVER LH
4. REMOVE SEAT TRACK BRACKET COVER OUTER FR
5. REMOVE SEAT TRACK BRACKET COVER INNER FR
6. REMOVE FRONT SEAT ASSEMBLY LH
7. REMOVE INSTRUMENT CLUSTER FINISH PANEL END
8. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
9. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1
10. REMOVE COIN BOX ASSEMBLY
11. REMOVE OUTER MIRROR SWITCH ASSEMBLY
12. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
13. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY No.2
14. REMOVE FR DOOR SCUFF PLATE LH
15. REMOVE FLOOR CARPET ASSEMBLY FRONT
16. CHECK AND ADJUST BRAKE PEDAL HEIGHT
a. Check brake pedal height.
Pedal height from asphalt sheet: 165.1 to 175.1 mm (6.49 to 6.89 inch)
b. If necessary, adjust brake pedal height.
1. Disconnect the connector from the stop lamp switch assembly.
2. Loosen the stop lamp switch lock nut and remove the stop lamp switch assembly.
3. Loosen the push rod lock nut.
4. Adjust the pedal height by turning the pedal push rod.
5. Tighten the push rod lock nut.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
6. Install the stop lamp switch assembly.
7. Connect the stop lamp switch assembly connector.
8. Push the brake pedal in 5 to 10 mm (0.20 to 0.39 inch), and turn the stop lamp switch assembly to lock the nut in the position where the stop lamp goes off.
9. After installation, push the brake pedal in 5 to 10 mm (0.20 to 0.39 inch), and check that the stop lamp comes on.
10. Tighten the stop lamp switch lock nut.
Torque: 17 Nm (173 kgf-cm, 12 ft. lbs.)
If the stop lamp does not come on, repeat the steps in (b).
17. CHECK PEDAL FREE PLAY
a. Stop the engine and depress the brake pedal several times until no vacuum remains in the booster.
b. Push in the pedal until the resistance begins to be felt, and then measure the distance as shown in the illustration.
Pedal free play: 1.0 to 6.0 mm (0.039 to 0.236 inch)
If incorrect, proceed to the following step.
1. Check the stop lamp switch clearance.
Stop lamp switch clearance: 0.5 to 2.4 mm (0.020 to 0.094 inch)
If correct, the pedal free play is OK.
If incorrect, adjust the stop lamp switch clearance.
18. CHECK PEDAL RESERVE DISTANCE
a. Release the parking brake pedal.
b. With the engine running, depress the pedal and measure the pedal reserve distance, as shown in the illustration.
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbs.): More than 105 mm (4.13 inch)
If incorrect, troubleshoot the brake system.
19. INSTALL FLOOR CARPET ASSEMBLY FRONT
20. INSTALL FR DOOR SCUFF PLATE LH
21. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2
22. INSTALL INSTRUMENT PANEL UNDER SAFETY PAD SUB-ASSEMBLY NO.1
23. INSTALL OUTER MIRROR SWITCH ASSEMBLY
24. INSTALL COIN BOX
25. INSTALL INSTRUMENT PANEL UNDER COVER NO.1
26. INSTALL CLUSTER FINISH PANEL CENTER LOWER
27. INSTALL INSTRUMENT CLUSTER FINISH PANEL END
28. INSTALL SEAT ASSEMBLY FR LH
29. INSTALL SEAT TRACK BRACKET COVER INNER FRONT
30. INSTALL SEAT TRACK BRACKET COVER OUTER FRONT
31. INSTALL SEAT TRACK OUTER COVER LH
32. INSTALL SEAT TRACK COVER RH
33. INSTALL SEAT BELT ANCHOR COVER CAP LH