Brake pedal
Pedal height
1. Measure the brake pedal height (see Figure 14.1) and check the measurement result for compliance with the requirements Specifications of this chapter.
Figure 14.1. Brake pedal height is the distance from the top of the pedal to the firewall when the pedal is not pressed.
If there is a discrepancy, adjust the pedal height as follows:
2. Remove the lower steering column trim panel and air intake duct.
3. Disconnect the wiring connector from the brake light contact sensor.
4. Loosen the brake light contact sensor lock nut and remove the contact sensor.
5. Loosen the brake pedal rod lock nut.
6. Adjust the pedal height by turning the rod.
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7. Tighten the brake pedal rod lock nut.
8. After installing the brake light contact sensor, screw it in until it lightly touches the brake pedal stopper.
9. Turn the brake light contact sensor back one turn.
10. Measure the distance (gap A) between the end of the threaded part of the brake light sensor and the brake pedal (see Figure 14.10) and check the measurement result for compliance with the requirements Specifications.
Figure 14.10. Gap A is the distance between the brake light contact sensor housing and the pedal lever.
If the gap size is not as specified, repeat the two previous steps and measure the gap again.
11. Tighten the brake light sensor lock nut.
12. Connect the wiring connector to the brake light sensor.
13. Check the operation of the brake light contact sensor: when the brake pedal is pressed, the brake light bulbs should light up, and when the pedal is released, they should go out.
14. Check the free travel of the brake pedal (see below).
Brake pedal free play
15. Turn off the engine if it was running and press the brake pedal several times until the vacuum in the vacuum booster is exhausted.
16. Press the brake pedal until you feel a slight resistance to pressing, then measure the distance between this point and the point where the pedal is in the released position (see figure 14.16).
Figure 14.16. Brake pedal free play is measured as the distance between the point where the pedal is fully released and the point where slight resistance to movement is felt.
Check the measurement result for compliance with the requirements Specifications.
17. If the free play does not meet the specifications, check the brake light sensor clearance (gap A in Figure 14.10). If it is normal, determine the fault in the brake system.
Brake pedal travel
18. Start the engine, press the brake pedal several times, then press the pedal firmly all the way down and hold it in this position.
19. The brake pedal reserve travel is measured from the floor to the top of the pedal when pressed. Check the measurement result for compliance with the requirements Specifications.
20. If the brake pedal reserve travel is less than specified, check the rear brake pad adjustment and/or the brake booster rod/master cylinder piston clearance. If the brake pedal "fails", bleed the brake system (see paragraph 10).