Brake Pedal Assy: Service and Repair
ON-CAR SERVICEBRAKE PEDAL
1) Check position of pedal pad.
Pedal height: L 148 mm (5.83 inch)
2) If it is not in specified value, adjust it by adjusting brake booster operating rod length.
3) Measure the clearance between threaded end of stop light switch and stopper. If it is not in specified value, adjust it by adjusting position of stop light switch.
CAUTION: Be careful not to rotate stop light switch.
Stop light switch clearance: A 0.3 mm (0.012 inch)
4) Apply grease to operating rod connecting pin to prevent it from wearing.
CLUTCH PEDAL
1) Check clutch pedal free play by operating pedal by hand.
Free play: L (At clutch pedal pad) 10 - 20 mm (0.39 - 0.79 inch)
Pedal height: Y 158 mm (6.22 inch)
Pedal stroke: A 140 - 145 mm (5.51 - 5.71 inch)
2) If it is not in specified value, adjust it by turning adjusting nut on engine side end of clutch cable.
Free play: L 2 - 4 mm (0.08 - 0.16 inch)
Full stroke: A 25.5 - 27 mm (1.004 - 1.063 inch)
3) Apply grease to connecting portion of clutch pedal and clutch cable.
Lock nut tightening torque: 5.9 ± 1.5 Nm (0.60 ± 0.15 kg-m, 4.3 ± 1.1 ft. lbs.)
ACCELERATOR PEDAL
Check pedal stroke and free play by operating accelerator pedal by hand. If it is not within specified value, adjust it by turning nut connecting accelerator cable to throttle body.
Free play at pedal pad: L 1 - 4 mm (0.04 - 0.16 inch)
Stroke at pedal pad: A 50 - 55 mm (1.97 - 2.17 inch)
Accelerator cable lock nut tightening torque: 14 ± 4 Nm (1.4 ± 0.4 kg-m, 10.1 ± 2.9 ft. lbs.)
REMOVAL
ACCELERATOR PEDAL
1) Disconnect ground cable from battery.
2) Disconnect accelerator cable from throttle body.
CAUTION: Be careful not to kink accelerator cable.
3) Remove instrument panel lower cover from instrument panel, and connector.
4) Disconnect accelerator pedal lever from accelerator
5) Working inside engine compartment, remove casing cap out of the toe board by turning it clockwise.
6) Pull out the cable from the toe board hole.
7) Remove accelerator pedal connecting bolt from accelerator pedal bracket.
BRAKE AND CLUTCH PEDAL
1) Disconnect ground cable from battery.
2) Disconnect clutch cable from release lever.
3) Remove instrument panel lower cover from instrument panel.
4) Disconnect the following parts from pedal bracket.
(1) Operating rod of brake booster
(2) Electrical connectors (for stop light switch, etc.)
5) Remove clevis pin which secures pedal to push rod.
6) Remove bolts and nuts which secure brake and clutch pedals, and remove pedal bracket and clutch cable as a unit.
CAUTION: Before removing clutch cable from toe board, remove grommet. Slowly remove clutch cable, being careful not to scratch it.
7) Depress clutch pedal, disconnect clutch cable from clutch pedal.
BRAKE PEDAL
1) Disconnect ground cable from battery.
2) Remove instrument panel lower cover from instrument panel.
3) Remove clevis pin which secures brake pedal to brake booster operating rod. Also disconnect stop lamp switch connector.
4) Remove two bolts and four nuts which secure brake pedal to pedal.
INSPECTION
BRAKE AND CLUTCH PEDALS
Move brake and clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kg, 2 lbs.) to ensure pedal deflection is in specified range.
CAUTION: If excessive deflection is noted, replace bushings with new ones.
Deflection of brake and clutch pedal:
Service limit: 5.0 mm (0.197 inch) or less
ACCELERATOR PEDAL
Lightly move pedal pad in lateral the direction to ensure pedal deflection is in specified range.
CAUTION: If excessive deflection is noted, replace bushing and clip with new ones.
Deflection of accelerator pedal:
Service limit: 5.0 mm (0.197 inch) or less
STOP LIGHT SWITCH
If stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one.
Specified position: L 2+1.5/0 mm (0.079+0.059/0 inch)
ASSEMBLY
BRAKE AND CLUTCH PEDAL
1) Attach stop light switch, etc. to pedal bracket temporarily.
2) Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring and clutch pedal effort reducing spring, and then install pedal bolt.
NOTE: Clean up inside of bushings and apply grease before installing spacer.
Tightening torque: T2: 29 ± 7 Nm (3.0 ± 0.7 kg-m, 21.7 ± 5.1 ft. lbs.)
4) Set brake pedal position by adjusting position of stop light switch.
Pedal position: L 125.9 mm (4.96 inch)
Tightening torque: T1: 8 ± 2 Nm (0.8 ± 0.2 kg-m, 5.8 ± 1.4 ft. lbs.)
ACCELERATOR PEDAL
Clean and apply grease to spacer and inside bore of accelerator pedal. Install accelerator pedal onto pedal bracket.
INSTALLATION
1) Installation is in the reverse order of removal procedures.
CAUTION:
- Be careful not to bend clutch cable too much.
- Never fail to cover outer cable end with boot.
- Be careful not to kink accelerator cable.
- Make sure that holder and casing cap are securely connected.
2) Adjust clutch pedal (2500 cc model)
3) Adjustment after pedal installation