Braking Sensor/Switch: Adjustments
Brake Pedal and Brake Pedal Position Switch/Idle Stop Switch AdjustmentPedal Height
1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise until it is no longer touching the brake pedal.
2. With CVT: Disconnect the idle stop switch connector, and turn the idle stop switch (B) counterclockwise until it is no longer touching the brake pedal.
3. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the right side of the pedal pad (D).
Standard Pedal Height (with carpet removed):
M/T: 184 mm (7 4/16 inch)
CVT: 188 mm (7 7/16 inch)
4. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed.
5. Brake pedal position switch adjustment: Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal army. Then, turn the switch 45 � clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.4 to 3.0 mm (0.016 - 0.118 inch) by locking the switch. Make sure the brake lights go off when the pedal is released.
6. With CVT: Idle stop switch adjustment: Adjust the idle stop switch (C). Screw in the idle stop switch until its plunger is fully pressed (threaded end (D) is touching the pad on the pedal arm). Then back off the switch 1/4 turn to make 0.3 mm (0.01 inch) of clearance between the threaded end and the pad. Tighten the locknut firmly. Connect the idle stop switch connector. When finished, start the engine, and warm it up to normal operating temperature (the radiator fan comes on), then make sure the engine stops when the brake pedal is pressed.
NOTE: these items during adjustment:
^ When either the brake pedal position switch or the idle stop switch needs adjusting, both switches must be adjusted together to keep their functions synchronized. Always adjust the brake pedal position switch first, then adjust the idle stop switch; never adjust the switches independently.
^ When the brake pedal is released, the brake pedal position switch is normally open and the idle stop switch is normally closed.
7. Check the brake pedal free play.
Pedal Free Play
1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the pedal by hand.
Free Play: 0.4 - 3.0 mm (0.016 - 0.118 inch)
2. If the pedal free play is out of specification, adjust the brake pedal position switch and idle stop switch (CTV Only). If the pedal free play is insufficient, it may result in brake drag.