Brake Pedal Assy: Adjustments

BRAKE: BRAKE PEDAL: ADJUSTMENT

ADJUSTMENT

1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Check the brake pedal height.





(1) Check the brake pedal height.
Standard pedal height from tibia pad:
120.5 to 130.5 mm (4.744 to 5.138 in.)
(b) Adjust brake pedal height.
(1) Turn the power switch OFF.
(2) Disconnect the connector from the stop light switch.
(3) Remove the stop light switch lock nut. Turn the switch so that the pedal has free play.
(4) Remove the brake master cylinder with simulator.





(5) Loosen the push rod lock nut, turn the push rod clevis and adjust length "A" shown in the illustration.
Length "A":
147.5 to 148.5 mm (5.807 to 5.846 in.)
(6) Tighten the push rod lock nut.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
(7) Install the brake master cylinder with simulator.





(8) Turn the stop light switch assembly so that its protrusion is between 0.5 and 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.
Torque: 17 Nm (170 kgf-cm, 12 ft-lbf)
(9) Connect the connector to the stop light switch.
(c) Adjust the brake pedal stroke sensor.
(1) Connect the Techstream to the DLC3.
(2) Loosen the 2 nuts.





(3) Turn the power switch ON (IG). While reading the stroke sensor 1 value shown on the Techstream, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
Standard voltage:
0.8 to 1.2 V
NOTE: Do not depress the brake pedal after turning the power switch ON (IG).
(4) Tighten the 2 nuts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
(d) Perform system initialization Programming and Relearning.
2. CHECK BRAKE PEDAL FREE PLAY
(a) Depress the brake pedal several times until no vacuum is left in the booster.






(b) Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.
Maximum pedal free play:
2.0 mm (0.079 in.)
If the pedal free play is 1 mm (0.04 in) or less, check the protrusion of the stop light switch shaft.
Protrusion of the stop light switch shaft:
0.5 to 2.4 mm (0.020 to 0.095 in.)
If the protrusion is off the specified value, adjust it.
If the protrusion is within the specified value, it is normal. However, brake pedal free play is 1.0 mm (0.039 in.) or less.
3. CHECK BRAKE PEDAL RESERVE DISTANCE






(a) Release the parking brake pedal.
(b) With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.
Standard pedal reserve distance from tibia pad at 200 N (20 kgf, 45 lbf):
More than 74 mm (2.91 in.)
If incorrect, troubleshoot the brake system Testing and Inspection.