Fig. 15.1. Location of brake system components without ABS
Fig. 15.2. Elements of the parking brake system
1. Remove the floor carpet and measure the brake pedal installation height above the floor (Fig. 15.3). If the pedal installation height is not correct, adjust it as follows.
Fig. 15.3. Measuring the brake pedal installation height
Brake pedal installation height: 163.5-166.5 mm
(1) Disconnect the connector from the brake light switch.
(2) Loosen the pusher lock nut and, using pliers, turn the pusher in one direction or the other to adjust the height of the brake pedal above the floor (Fig. 15.4).
Fig. 15.4. Adjusting the height of the brake pedal above the floor
(3) Tighten the push rod lock nut.
(4) Press the brake light switch fully towards the brake pedal. The switch will only move when pressed firmly.
(5) Raise the brake pedal until the plunger comes out completely, then move the brake light switch to the required position. Rotate the brake light switch to adjust its position so that the gap is within 0.5-1.0 mm (Fig. 15.5).
Fig. 15.5. Location for measuring the gap between the brake light switch rod and the brake pedal
(6) Connect the connector to the brake light switch.
(7) Check that the brake lights go out when you release the brake pedal.
2. With the engine off, press the brake pedal several times to remove the vacuum in the brake booster. Press the brake pedal by hand until you feel a noticeable resistance and measure the free travel of the pedal (Fig. 15.6).
Fig. 15.6. Location for measuring free travel of the brake pedal
Brake pedal free play: 3-8 mm
If the brake pedal free play exceeds the permissible value, the gap in the connection between the brake pedal and the pedal bracket is probably increased. Check the gap and, if necessary, replace damaged parts.
3. Start the engine, press the brake pedal with a force of 490 N and measure the distance between the pedal and the floor (Fig. 15.7).
Fig. 15.7. Location for measuring the distance between the floor and the brake pedal when pressed
Distance between the floor and the brake pedal when pressed: not less than 80
If the measured distance is not as required, check for air in the hydraulic brake system, clearance between the brake shoes and drum, or parking brake drag. Adjust and replace faulty parts as necessary.