Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION

1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet: 153.3 - 163.3 mm (6.035 - 6.429 inch)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
a. Remove the lower No. 1 instrument panel and lower LH instrument panel insert.
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.
h. Connect the connector to the stop light switch.
i. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), turn the stop light switch to lock the nut in the position where the stop light goes off.
l. After installation, push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), check that stop light lights up.
k. After adjusting the pedal height, check the pedal freeplay.
l. Install the lower LH instrument panel insert and lower No. 1 instrument 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 beginning of the resistance is felt, then measure the distance.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 inch)
If incorrect, check the stop light switch clearance.
If the clearance is OK, then troubleshoot the brake system.
Stop light switch clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch)

HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 1 - 6 mm (0.04 - 0.24 inch) at the pedal.

4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake. 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 75 mm (3.0 inch)
If the reserve distance is incorrect, troubleshoot the brake system.