Stop Light Switch
Pedal Push Rod
Pedal Freeplay
Asphalt SheetPedat Height
BRAKE SYSTEM - Checks and
CHECKS AND ADJUSTMENTS
CHECK AND ADJUSTMENT OF BRAKE PEDAL
1. CHECK THAT PEDAL HEIGHT IS CORRECT' AS
SHOWN
Pedat heisht from asphalt slreet:
i#;:?ifil.,
IF NECESSARY. ADJUST PEDAL HEIGHT
(a) Sufficiently loosen the stop light switch.
(b) Adjust the pedal height by turning the pedal push
rod.
(c) Return the stop light switch until it lightly contacts
the pedal stopper.
(d) After adjusting the pedal height, check and adiust the
pedal freePlay.
CHECK THAT PEDAL FREEPLAY IS CORRECT, AS
SHOWN
(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 resistance is
felt. Measure the distance, as shown'
Pedaf freepfay: 3 - 6 mm (0.12 - O,24 in.l
NOTE: The pedal freeplay is the amount of the stroke
until the booster air valve is moved by the pedal push rod.
IF NECESSARY, ADJUST PEDAL FREEPLAY
(a) lf incorrect adiust the pedal freeplay by turning the
pedal Push rod.
(b) Start the engine and check that pedal freeplay exists.
(c) After adjusting the pedal freeplay, check the pedal
height.
CHECK THAT PEDAL RESERVE DISTANCE IS
CORRECT, AS SHOWN
(a) Release the parking brake.
(b) With engine running, depress the pedal and measure
the pedal reserve distance, as shown.
Pedaf reserve distance at 50 kg (1 1 O-2 1b,490 Nl:
More than 90 mm (3.54 in.l
lf incorrect, troubleshoot the brake system.
BRAKE SYSTEM - Checks and AdjustmentsBR-7
@@
VV
1 st 2nd
OPERATIONAL TEST OF BRAKE BOOSTER
NOTE: lf available, use a brake booster tester to check
the booster operating condition.
1. OPERATING CHECK
(a) Depress the brake pedal several times with the
engine off, and check that there is no change in the
pedal reserve distance.
(b) Depress the brake pedal and start the engine. lf the
pedal goes down slightly, operation is normal.
2. AIR TIGHTNESS
(d Start the engine and stop it after one or two minutes.
Then depress the brake pedal several times slowly. lf
the pedal goes down fartherest the first time, and
less the second and third time, the boo$ter is air
tight.
(b) Depress the brake pedal while the engine is running,
and stop it with the pedal depressed. lf there is no
change in pedal reserve travel after holding the pedal
for thirty seconds, the booster is air tight.
BLEEDING OF BRAKE SYSTEM
NOTE: lf 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 immediataly.
1. FILL BRAKE RESERVOIRS WITH BRAKE FLUID
Check the reservoir after bleeding each wheel. Add fluid, if
necessary.
2, CONNECT VINYL TUBE TO WHEEL CYLINDER
BLEEDER PLUG
lnsert the other end of the tube in a half-full container of
brake fluid.
3. BLEED BRAKE LINE
(a) Slowly pump the brake pedal several times.
(b) While an assistant depresses the pedal, loosen the
bleeder plug until fluid starts to runout. Then close
the bleeder plug.
(c) Repeat this procedure until there are no more air bub-
bles in the fluid.
Bleeder plug tightening torque:
85 kg-cm (74 in.-lb,8.3 N.m)
4. REPEAT PROCEDURE FOR EACH WHEEL
