Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION





1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
Standard Pedal: 139.8 - 149.8 mm (5.504 - 5.898 inch)
Sport Pedal: 141.1 - 151.1 mm (5.555 - 5.949 inch)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
a. Remove the lower No. 1 panel and finish panel.
b. Disconnect the connector from the stop light switch.
c. Turn the stop light switch counterclockwise and remove the stop light switch.
d. Loosen the clevis lock nut.
e. Adjust the pedal height by turning the pedal push rod.
f. Tighten the clevis lock nut.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)





g. Insert the stop light switch until the body hits the cushion.

NOTICE: When inserting the stop light switch, support the pedal from behind so that the pedal is not pushed in.

h. Make a quarter turn clockwise to install the stop light switch.

NOTICE: The turning torque for installing the stop light switch should be 1.5 Nm (15 kgf-cm, 13 ft. lbs.) or less.

HINT: Due to the inverse screw structure, if the stop light switch is turned clockwise, the stop light switch moves in the direction to be pulled out.

i. Connect the connector to the stop light switch.
j. Check the protrusion of the rod.
Protrusion of the rod: 1.5 - 2.5 mm (0.059 - 0.098 inch)
k. After adjusting the pedal height, check the pedal free play.





3. CHECK PEDAL FREE PLAY
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 until the beginning of the resistance is felt. Measure the distance, as shown.
Pedal free play: 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.





4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake lever.
With 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 85 mm (3.35 inch)
If incorrect, troubleshoot the brake system.