Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION





1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet: 127 - 137 mm (5.08 - 5.48 inch)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the front door scuff plate, cowl side trim, lower finish panel and finish panel.
(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 clevis lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
(f) Tighten the clevis lock nut.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
(g) Install the stop light switch.
(h) Connect the connector to the stop light switch.
(i) 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.
(j) 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.
(l) Install the finish panel, lower finish panel, cowl side trim and front door scuff plate.





3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal more than 40 times until there is no more pressure left in the booster.
(b) Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 inch)
If incorrect, check the stop light switch clearance.
If the clearance is OK, then troubleshoot the brake system.
Stop light switch clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch)





4. 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 200 N (20 kgf, 45 lbs.): More than 85 mm (3.35 inch)
If incorrect, troubleshoot the brake system.