1995 > G 2.0 DOHC

INSPECTION

Pedal Height 1. Check that the distance from the top center of the pedal pad to the dash panel is within specification Pedal height: 8.90 - 9.10 inch (226 - 231 mm) INSPECTION Pedal Play 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Lightly depress the pedal by hand and check the pedal play (depress until the valve plunger contacts the stopper plate, and resistance is felt). Pedal play: 0.16 - 0.28 inch (4 - 7 mm) INSPECTION Pedal-to-Floor Clearance 1. Check that the distance from the floor panel to the center of the upper surface of the pedal pad is as specified when the pedal is depressed with a force of 152 lb (69 kg, 677 N) Pedal-to-floor clearance: 4.61 inch (117 mm) min. If the distance is less than specified, check for the following: A. Air in the brake system. B. Malfunction of the automatic adjuster (for drum brakes). Brake Fluid Replacement 1. Remove the brake fluid from the reservoir using a suction pump. 2. Fill the reservoir with new brake fluid. 3. Attach a transparent vinyl tube to the bleeder screw and place the other end into a container. 4. Have an assistant apply and hold pressure to the brake pedal. 5. Loosen the bleeder screw at the wheel farthest from the brake master cylinder (right rear) and bleed brake circuit until brake pedal makes contact with the floor. 6. Tighten the bleeder screw and release the brake pedal. 7. Bleed brake circuit until fresh, clear fluid flows from the bleeder screw. 8. Repeat operation at remaining 3 wheels. Parking Brake Stroke 1. Check that the stroke is within specification when the parking brake lever is pulled with a force of 22 lb (10 kg, 98 N). Stroke: 6 - 8 notches ADJUSTMENT Pedal Height 1. Disconnect the stop light switch connector. 2. Loosen lock nut “1” and turn switch “A” until it does not contact the pedal. 3. Loosen lock nut “2” and turn rod “C” to adjust the height. 4. Adjust the pedal free play and then tighten operating rod lock nut. Tighten lock nut to 21 lb·ft (29 N·m) 5. Turn the stop light switch until it contact the pedal and then turn an additional 1/2 turn. Then tighten lock nut. Tighten lock nut to 11.5 lb·ft (15.7 N·m) 6. Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released. ADJUSTMENT Pedal Play 1. Loosen lock nut “D” or rod “C” and turn the rod to adjust the free play. 2. Tighten lock nut. AIR BLEEDING PROCEDURE • The fluid in the reservoir must be maintained at the 3/4 lever, or higher, during air bleeding. • Do not allow brake fluid to make contact with any painted surface. If any brake fluid makes contact, wash off immediately. 1. Jack up the vehicle and support it with safety stands. 2. Fill the reservoir with brake fluid. Be sure that the reservoir is at least 3/4 full at all times during the air bleeding process. 3. After removing the bleeder cap, connect one end or a transparent vinyl tube to the bleeder screw and place the other end in a receptacle. • Two people are required for this procedure and they should stay in voice contact with each other. • Be sure the pedal remains depressed until the air bleed screw is tightened. 4. One person should depress the brake pedal a few times, and then hold it in the depressed position. 5. A second person should loosen the bleeder screw, drain out the fluid, and retighten the screw. • After tightening the bleeder screw, check to be sure that there is no fluid leakage. • Be sure to clean away any spilled fluid. 6. Repeat steps 4 and 5 until no air bubbles are seen in the tube. 7. After bleeding off the air, add brake fluid to the reservoir until the “MAX” line is reached.

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