Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION





1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
Except convertible: 152.0 - 162.0 mm (5.984 - 6.378 inch)
Convertible: 146.0 - 156.0 mm (5.748 - 6.142 inch)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
a. Remove the cowl side trim, No. 1 lower panel and lower panel insert.
b. Disconnect the connector from the stoplight switch.
c. Loosen the stoplight switch lock nut and remove the stoplight 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 stoplight switch.
h. Push in the brake pedal 5 - 15 mm (0.20 - 0.59 inch), turn the stoplight switch to lock the nut in the position where the stoplight goes off.
i. Connect the connector to the stoplight switch.
j. After installation, push in the brake pedal 5 - 15 mm (0.20 - 0.59 inch), check that stoplight lights up.
k. After adjusting the pedal height, check the pedal freeplay.
l. Install the lower panel insert, No. 1 lower panel and cowl side trim.





3. CHECK PEDAL FREEPLAY
a. Stop the engine and depress the brake pedal more than 10 times until there is no more pressure left in the booster.
b. Push in the pedal by hand until the second point of resistance begins to be felt, then measure the distance, as shown.
Pedal freeplay: 1.0 - 6.0 mm (0.039 - 0.236 inch)
If incorrect, check the stoplight switch clearance. If the clearance is OK, then troubleshoot the brake system.
Stoplight switch clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch)

HINT: The freeplay to the 1st point of resistance is due to the play between the clevis, pedal rink and pin. It is 1.0 - 6.0 mm (0.039 - 0.236 inch) on the pedal.





4. CHECK PEDAL RESERVE DISTANCE
a. Remove the floor carpet.
b. Release the parking brake.
c. 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, 110.1 lbs.): More than 60 mm (2.36 inch)
If the reserve distance is incorrect, troubleshoot the brake system.