Brake Pedal Assy: Testing and Inspection

BRAKE PEDAL SUB-ASSEMBLY

ON-VEHICLE INSPECTION








1. CHECK BRAKE PEDAL HEIGHT
a. Check the brake pedal height.
Pedal height from dash panel: 158.1 to 168.1 mm (6.224 to 6.618 inch)

NOTICE: Do not adjust the pedal height. Doing so by changing the push rod length will structurally change the pedal ratio.

If the pedal height is incorrect, adjust the rod operating adapter length.








b. Adjust the rod operating adapter length.
(1) Remove the clip and clevis pin.
(2) Loosen the clevis lock nut.
(3) Adjust the rod operating adapter length by turning the pedal push rod clevis.
Rod operating adapter length A:
214 to 224 mm (8.425 to 8.818 inch) for w/ VSC
212 to 222 mm (8.346 to 8.740 inch) for w/o VSC
(4) Tighten the clevis lock nut.
Torque: 25.5 Nm (260 kgf-cm, 19 ft. lbs.)
(5) Install the clip and clevis pin.
- If the pedal height is incorrect even when the rod operating adapter is adjusted, check that there is no damage in the brake pedal, brake pedal lever, brake pedal bracket or dash panel.
- Even if there is damage, there is no problem if the reserve distance is within the standard value.
- If necessary, replace the parts.
2. CHECK AND ADJUST STOP LAMP SWITCH

HINT: If the pedal height is incorrect, check and adjust the stop lamp switch.

a. Disconnect the stop lamp switch connector from the stop lamp switch.
b. Turn the stop lamp switch counterclockwise, and remove the stop lamp switch.





c. Insert the stop lamp switch until the body comes into contact with the cushion.

NOTICE:
- When inserting the stop lamp switch, support the pedal from behind so that the pedal is not pushed in.
- Take care not to depress the pedal during the operation.





d. Make a quarter turn clockwise to install the stop lamp switch.

NOTICE: The turning torque for installing the stop lamp switch:

Torque: 1.5 Nm (15 kgf-cm, 13 inch lbs.) or less

HINT: Due to the inverse screw structure, turning the stop lamp switch clockwise will cause it to become loose and eventually detach from the adjuster.

e. Connect the stop lamp switch connector to the stop lamp switch.
f. Check the protrusion of the rod.
Protrusion of the rod: 1.5 to 2.5 mm (0.059 to 0.098 inch)








3. CHECK PEDAL FREE PLAY
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 until the beginning of the resistance is felt. Measure the distance as shown.
Pedal free play: 1 to 6 mm (0.04 to 0.24 inch)





4. CHECK PEDAL RESERVE DISTANCE
a. Release the parking brake pedal. With the 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 ft. lbs.): More than 55 mm (2.17 inch)
If incorrect, troubleshoot the brake system.