Brake Pedal Assy: Testing and Inspection

BRAKE PEDAL HEIGHT INSPECTION
1. Verify the distance from the center of the upper surface of the pedal pad to the carpet is as specified.
^ If not as specified, adjust the brake pedal height.
Pedal height (reference value)
186 mm (7.32 inch)

BRAKE PEDAL HEIGHT ADJUSTMENT
1. Loosen locknut B and turn adjusting bolt A until it does not contact the pedal.





2. Loosen locknut D and turn rod C to adjust the height.
3. Tighten locknut D.
Tightening torque
24 - 34 Nm (2.4 - 3.5 kgf-m, 18 - 25 ft. lbs.)
4. Turn adjusting bolt A so that clearance E between adjusting bolt A and the pedal is 0.1 - 1.0 mm (0.004 - 0.039 inch).
5. Tighten locknut B.
Tightening torque
14 - 17 Nm (140 - 180 kgf-cm, 122 - 156 inch lbs.)
6. Verify that clearance F is obtained at any position of the pedal full stroke.
7. Verify that the lock unit operates correctly.

Caution
^ When the brake pedal height is adjusted, a new brake switch must be used.
^ The new switch can be adjusted only once.
^ Pulling or pushing the tip of the new brake switch can damage the inner parts.

8. Install a new brake switch.





Note The new brake switch projection height is adjusted automatically in step 7.

9. Pull the brake pedal until you hear the tip of the brake switch click.
10. Inspect the pedal play and the brake light operation. If the brake light does not operate, replace the brake switch and repeat steps 6-8.

BRAKE PEDAL PLAY INSPECTION
1. Depress the pedal several times to eliminate the vacuum in the system.
2. Remove the snap pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin.





3. Gently depress the pedal by hand until resistance is felt, and inspect for the play. If not within the specification, adjust the brake pedal play.
Pedal play
7.8 - 12 mm (0.31 - 0.47 inch)

BRAKE PEDAL PLAY ADJUSTMENT
1. Remove the snap pin and clevis pin.





2. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal.
3. Install the clevis pin and the snap pin.
4. Tighten locknut D.
Tightening torque
24 - 34 Nm (2.4 - 3.5 kgf-m, 18 - 25 ft. lbs.)
5. Perform step 6 through step 11 from the "Brake Pedal Height Adjustment".

PEDAL-TO-FLOOR CLEARANCE INSPECTION





1. Start the engine and verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is depressed with a force of 589 N (60 kgf, 132 lbs.).
^ If the distance is less than specified, inspect for the air in brake system.
Specification
53 mm (2.1 inch) min.