Remove the carpet and measure the brake pedal height. If the height is over the standard value, adjust it as the following procedures.

(1)

Disconnect the stop lamp switch connector, loosen the stop lamp switch lock nut, and back off the stop switch until it doesn't reach the brake pedal arm.

(2)

Loosen the push rod lock nut, and screw the push rod in or out with pliers until the standard pedal height from the floor is reached.

(3)

Turn the stop lamp switch until clearance between the stop lamp switch outer case and stopper becomes 0.5~1.0mm.

Tighten the lock nut firmly.

note

Brake pedal stroke should be 130mm (5.12 in.) or more. If the brake pedal stroke is not 130mm or more, readust the brake pedal height and stop lamp switch clearance.

(6)

With the engine off, depress the pedal 2~3 time to get rid of pressure, and then inspect the play on the pedal by pushing it by hand.

: 3 ~ 8 mm (0.11 ~ 0.31 in.)

If the play is below the standard value, check on the fact that the clearance between the stop lamp switch outer case and the brake pedal is within the standard value.

If the play is over the standard value, clearance between the clevis pin and the brake pedal arm is over the standard value. Inspect the defective parts and replace them if required.

Remove the carpet and measure the brake pedal height. If the height is over the standard value, adjust it as the following procedures.

(2)

Loosen the push rod lock nut, and screw the push rod in or out with pliers until the standard pedal height from the floor is reached.

caution

For RHD vehicle, the push rod is connected to the brake pedal lever, not to the pedal.

(3)

Turn the stop lamp switch until clearance between the stop lamp switch outer case and stopper becomes 0.5~1.0 mm(0.02~0.04 in.).

Tighten the lock nut firmly.

note

Brake pedal stroke should be 130 mm (5.12 in.) or more. If the brake pedal stroke is not 130 mm or more, readjust the brake pedal height and stop lamp switch clearance.

(6)

With the engine off, depress the pedal 2~3 time to get rid of pressure, and then inspect the play on the pedal by pushing it by hand.

Standard value : 3 ~ 8 mm (0.11 ~ 0.31 in.)

If the play is below the standard value, check on the fact that the clearance between the stop lamp switch outer case and the brake pedal is within the standard value.

If the play is over the standard value, clearance between the clevis pin and the brake pedal arm is over the standard value. Inspect the defective parts and replace them if required.

Run the engine for one or two minutes, and then shut it off. Depress the brake pedal several times at normal foot pressure. If the pedal goes down further at first but rises gradually after the second or third time, the brake booster is functioning properly. If the pedal height doesn't change, the booster is damaged.

With the engine off, depress the brake pedal several times and check on the pedal height change. After that, with the pedal depressed, start the engine. If the pedal goes down slightly, the booster is in good condition. If the pedal height doesn't change, the booster is damaged.

With the engine running, depress the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition. if the pedal goes up, the booster is damaged.

If one of the above three tests is not okay, check the vacuum hoses and the brake booster and make any necessary corrections. If all tests are OK, the booster is good.

Remove the vacuum hose.

note

The check valve is press-fitted inside the vacuum hose at the position of the marking.

Check the operation of the check valve by using a vacuum pump.

caution

If the check valve is defective, replace it if an assembly unit together with the vacuum hose.

Remove the reservoir cap and fill the brake reservoir with brake fluid.

note

When bleeding pressurized fluid, do not depress the brake pedal.

Connect a vinyl tube to the wheel cylinder bleeder plug, and insert the other end of tube in the container of brake fluid.

Depress the brake pedal several times.

While depressing the brake pedal fully, loosen the bleeder plug until the fluid starts to run out. Then close the bleeder plug.

Repeat the steps 3 and 4 until there are no more bubbles in the fluid.

Tighten the bleeder plug screw.

Repeat the above procedure for each wheel in the sequence shown in the illustration.

After bleeding, depress the brake pedal 20 times with a force of over 10 kgf.

Pull the brake lever to full stroke more than 3 times.

When pulling the lever (pulling point : at 25mm (0.98 in.) from the lever assembly end as shown in the illustration), it should be locked at 6~8 clicks.

Adjust the parking brake if the lever clicks are out of standard value.

The indicator light will go out when the brake lever is fully released, and will light up with the lever pulled one notch. If it does not operate properly, replace it.

After adjustment, check that the rear brakes do not drag with the parking brake lever released.