Brakes and Traction Control: Adjustments
BRAKE PEDAL HEIGHT
Pedal height from asphalt sheet: 177.5-187.5 mm (6.988-7.382 in.)
If incorrect, adjust the pedal height.
ADJUST PEDAL HEIGHT
- If necessary, remove the instrument lower finish panel and air duct.
- Loosen the stop light switch lock nut.
- Sufficiently loosen the stop light switch.
- Loosen the push rod lock nut.
- Adjust the pedal height by turning the pedal push rod
- Return the stop light switch until it lightly contacts the pedal stopper.
- Tighten the two lock nuts.
- Check that the stop lights light with the brake pedal depressed.
- After adjusting the pedal height, check and adjust pedal freeplay.
CHECK THAT PEDAL FREEPLAY IS CORRECT
- Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
- (Push in the pedal until the beginning of resistance is felt. Measure the distance, as shown.
Pedal freeplay: 3-6 mm (0.12-0.24 in.)
NOTE: The freeplay to the first resistance is due to the play between the clevis and pin. And it is 1 - 3 mm (0.04 - 0.12 in.) on the pedal.
ADJUST PEDAL FREEPLAY
- If incorrect, adjust the pedal freeplay by turning the pedal push rod.
- Start the engine and confirm that pedal freeplay exists.
- After adjusting the pedal freeplay, check the pedal height.
- Install the air duct and instrument lower finish panel.
CHECK PEDAL RESERVE DISTANCE
- Release the parking brake. With engine running, depress the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 50 kg (110.2 lb): More than 85 mm (3.35 in.)
- If incorrect, troubleshoot the brake system.
BLEEDING THE BRAKE SYSTEM
NOTE: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air.
CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.
- Check the fluid level in the reservoir. If necessary, add brake fluid.
NOTE: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air from the master cylinder.
- Disconnect the brake tubes from the master cylinder.
- Have a helper depress the brake pedal and hold it.
- Block off the outer holes with your fingers, and release the brake pedal.
- Repeat three or four times.
- Reconnect the brake tubes to the master cylinder.
- Refill the master cylinder.
- Begin bleeding air from brake or wheel cylinder with longest hydraulic line.
- Connect the vinyl tube to the brake or wheel cylinder bleeder plug, and insert the other end of tube in a half full container of brake fluid.
- Slowly pump the brake pedal several times.
- While having an assistant press on the pedal, loosen the bleeder plug until fluid starts to runout. Then close the bleeder plug.
- Repeat until there are no more air bubbles in the fluid.
- Tighten the bleeder plug.
Bleeder Plug Tightening Torque: 85 kg-cm (74 in.-lb, 8.3 N.m)
- Repeat procedure for each wheel
CHECK ADJUSTMENT OF PARKING BRAKE (DRUM BRAKES)
- Pull the parking brake lever all the way up, and count the number of clicks.
Parking brake lever travel at 20 kg (44.1 lb): 5 - 8 clicks
- If incorrect, adjust the parking brake.
ADJUST PARKING BRAKE LEVER TRAVEL
NOTE: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted.
- Remove the brake drum.
- Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
- Remove the console box.
- Loosen the lock nut and turn the adjusting nut until the lever travel is correct.
- Tighten the lock nut.
Torque: 65 kg-cm (48 in.-lb. 5.4 N.m)
- Install the console box.
ADJUST PARKING BRAKE (DISC REAR BRAKES)
- Remove rear wheels.
- Temporarily reinstall the hub nuts.
- Remove the hole plug.
- Turn the adjuster and expand the shoes until the rotor disc locks.
- Return the adjuster eight notches.
- Install the hole plug.