1. INSPECT BRAKE PEDAL HEIGHT
(a) Check the brake pedal height.
Pedal height from dash panel: 150.3 to 160.3 mm (5.917 to 6.311 in.)
NOTICE: Do not adjust the pedal height. Doing so by changing the push rod length will structurally change the pedal ratio.
2. CHECK AND ADJUST STOP LIGHT SWITCH
(a) Disconnect the stop light switch assembly connector from the stop light switch assembly.
(b) Turn the stop light switch assembly counterclockwise and remove the stop light switch assembly.
(c) Insert the stop light switch assembly until the body hits the cushion.
NOTICE: When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.
(d) Make a quarter turn clockwise to install the stop light switch assembly.
NOTICE:
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
(e) Connect the stop light switch connector to the stop light switch assembly.
(f) Check the protrusion of the rod.
Protrusion of the rod: 0.5 to 2.5mm (0.020 to 0.098 in.)
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 to 6 mm (0.04 to 0.24 in.)
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake pedal.
With the 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 lbf): More than 52 mm (2.0 in.)
HINT: If the distance is out of the specification, troubleshoot the brake system.
Diagnosis system
DESCRIPTION
(a) When troubleshooting OBD II (On-Board
Diagnostics) vehicles, an intelligent tester
(complying with SAE J1987) must be connected to
the DLC3 (Data Link Connector 3) of the vehicle.
Various data in the vehicle's ECM (Engine Control
Module) can be then read.
(b) OBD II regu ...
Diagnosis system
1. CHECK DLC3
The vehicle's ECU uses ISO 15765-4 for
communication protocol. The terminal arrangement
of the DLC3 complies with SAE J1962 and matches
the ISO 15765-4 format
NOTICE:
*: Before measuring the resistance, leave the
vehicle as is for at least 1 minute and do not
oper ...
Reassembly
1. INSTALL MAGNETIC CLUTCH ASSEMBLY
(a) Install the magnetic clutch stator while aligning the
protrusion on the stator with the notch on the air
compressor assembly as shown in the illustration.
(b) Using a snap ring expander, install a new snap ring
with the chamfered side facing up.
...