Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from dash panel: 124.3 - 134.3 mm (4.894 - 5.287 inch)
If the pedal height is incorrect, adjust it.





2. IF NECESSARY, ADJUST PEDAL HEIGHT
a. Disconnect the connector from the stoplight switch.
b. Loosen the stoplight switch lock nut and remove the stoplight switch.
c. Loosen the push rod lock nut.
d. Adjust the pedal height by turning the pedal push rod.
e. Tighten the push rod lock nut.
Torque: 26 Nm (260 kgf-cm, 20 ft. lbs.)
f. Install the stoplight switch.
g. Connect the connector to the stoplight switch.
h. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), turn the stoplight switch to lock the nut in the position where the stoplight goes off.
i. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), check that stoplight lights up.
j. 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 by hand until the resistance begins to be felt, then measure the distance, as shown.
Pedal free play: 1 - 3 mm (0.04 - 0.12 inch)
If incorrect, check the stoplight switch clearance. If the clearance is OK, then troubleshoot the brake system.
Stoplight switch clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch)





4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake lever.
With the engine running, depress the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance from dash panel at 490 N (50 kgf, 110.2 ft. lbs.): More than 48 mm (1.89 inch)
If the reserve distance is incorrect, troubleshoot the brake system.