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Check and Adjustment

This document provides instructions for checking and adjusting the brake system on a vehicle. It describes how to check the brake pedal height and free play, how to bleed air from the brake lines, how to check the brake booster operation, and how to adjust the parking brake lever travel. The specifications for the pedal height, free play, reserve distance, and parking brake lever travel are provided. Bleeding the brake lines involves connecting a vinyl tube from the wheel cylinder bleeder plug to a brake fluid container, then loosening the plug while an assistant depresses the brake pedal to force out air bubbles.

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johansen05
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227 views

Check and Adjustment

This document provides instructions for checking and adjusting the brake system on a vehicle. It describes how to check the brake pedal height and free play, how to bleed air from the brake lines, how to check the brake booster operation, and how to adjust the parking brake lever travel. The specifications for the pedal height, free play, reserve distance, and parking brake lever travel are provided. Bleeding the brake lines involves connecting a vinyl tube from the wheel cylinder bleeder plug to a brake fluid container, then loosening the plug while an assistant depresses the brake pedal to force out air bubbles.

Uploaded by

johansen05
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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BRAKE SYSTEM

CHECK AND ADJUSTMENT

BR7

CHECK AND ADJUSTMENT


BRAKE PEDAL CHECK AND ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN
Pedal height from asphalt sheet: 2WD: 148 mm (5.83 in.) 4WD: 145 mm (5.71 in.)

2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Disconnect the connector from the stop light switch. (b) Loosen the stop light switch lock nut and remove the stop light switch. (c) Loosen the push rod lock nut. (d) Adjust the pedal height by turning the pedal push rod. (e) Tighten the push rod lock nut.
Torque: 25 Nm (260 kgfcm, 19 ftlbf)

(f)

Install the stop light switch and turn it until it lightly contacts the pedal stopper. (g) Turn the stop light switch back one turn. (h) Check that the clearance (A) between stop light switch and pedal.
Clearance: 0.52.4 mm (0.020.09 in.)

(i) (j) (k)

Tighten the stop light switch lock nut. Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released. After adjusting the pedal height, check the pedal free play. HINT: If clearance (A) between the stop light switch and the pedal stopper has been adjusted correctly, the pedal freeplay will meet the specifications.

BR8

BRAKE SYSTEM

CHECK AND ADJUSTMENT

3.

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) Single booster: Push in the pedal until the beginning of resistance is felt. Measure the distance, as shown.
Pedal freeplay: 36 mm (0.120.24 in.)

Tandem booster: Push in the pedal by hand until the beginning of the second resistance is felt. Measure the distance, as shown.
Pedal freeplay: 36 mm (0.120.24 in.)

HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 13 mm (0.040.12 in.) at the pedal.

4.

CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT, AS SHOWN Release the parking brake. With engine running, depress the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): 2WD: 22RE Engine More than 70 mm (2.76 in.) 3VZE Engine More than 65 mm (2.56 in.) 4WD: More than 65 mm (2.56 in.)

If incorrect, troubleshoot the brake system.

BRAKE SYSTEM

CHECK AND ADJUSTMENT

BR9

BRAKE BOOSTER OPERATIONAL TEST


HINT: If 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 engine. If the pedal goes down slightly, operation is normal. 2. AIR TIGHTNESS CHECK (a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down furthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop it with the pedal depressed. If there is no change in pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight.

BRAKE SYSTEM BLEEDING


HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary.

1.

2.

BLEED MASTER CYLINDER HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it.

(c)

Block off the outlet plug with your finger, and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times.

BR10

BRAKE SYSTEM

CHECK AND ADJUSTMENT

3.

CONNECT VINYL TUBE TO WHEEL CYLINDER BLEEDER PLUG Insert other end of the tube in a halffull container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. BLEED BRAKE LINE (a) Slowly depress the brake pedal several times. (b) While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then close the bleeder plug. (c) Repeat this procedure until there are no more air bubbles in the fluid.
Bleeder plug tightening torque: 11 Nm (110 kgfcm, 8 ftlbf)

5. 6.

REPEAT PROCEDURE FOR EACH WHEEL BLEED LSP & BV

PARKING BRAKE CHECK AND ADJUSTMENT


1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS CORRECT Pull the parking brake level all the way up, and count the number of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 2WD: 1218 clicks 4WD: 1117 clicks

2.

IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. 2WD: (a) Tighten the adjusting nut until the travel is correct. Then tighten the lock nut. (b) After adjusting the parking brake, confirm that the rear brakes are not dragging.

4WD: (a) Tighten one of the adjusting nuts of the intermediate lever while loosening the other one until the travel is correct. Tighten the 2 adjusting nuts. (b) After adjusting the parking brake, confirm that the bellcrank stopper screw comes into contact with the backing plate.

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