Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION





1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet: 154 - 164 mm (6.063 - 6.457 inch)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
a. Remove the lower 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 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 and turn it until it slightly contacts the pedal stopper.
h. Connect the connector to the stop light switch.
i. Push in the brake pedal 5 - 10 mm (0.20 - 0.39 inch), turn the stop light switch to lock the nut in a position where the stop light goes off.
j. After installation, push in the brake pedal 5 - 10 mm (0.20 - 0.39 inch), check that stop light lights up.
k. After adjusting the pedal height, check the pedal freeplay.
l. Install the lower finish panel.





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 resistance begins to be felt, then measure the distance.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 inch)

HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 2.0 - 4.5 mm (0.08 - 0.18 inch) at the pedal.

If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system.
Stop light switch clearance: 1.5 - 2.5 mm (0.059 - 0.098 inch)





4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake lever.
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 lbs.): More than 99 mm (3.90 inch)
If the reserve distance is incorrect, troubleshoot the brake system.