Brake Pedal Assy: Service and Repair

Brake, Accelerator, and Clutch Pedal Replacement

Special Tools

* DT-6202-A - Pliers

* DT-6202-B - Pliers

* DT-6202-20 - Adapter to DT-6202-A

* DT-50894 - Remover

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Remove the battery. Refer to Battery Replacement Removal and Replacement.

2. Remove the battery tray. Refer to Battery Tray Replacement Service and Repair.





Note: Do NOT disconnect the engine coolant hoses.

3. Remove the radiator surge tank clip (2).

4. Remove the radiator surge tank (1).

5. Position the radiator surge tank (1) aside.




6. Remove the BPMV bracket bolts (1).




7. Remove the brake booster bolts (1).





Note:

* Do NOT open the hydraulic brake system.

* Second mechanic is required.

8. Pull the brake booster and the BPMV assembly forward in order to get an access to the brake pedal bracket nuts (1).

9. Remove the brake pedal bracket nuts (1).

10. Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement (without Knee Airbag) Instrument Panel Lower Trim Pad Cover Replacement (without Knee Airbag)Instrument Panel Lower Trim Pad Cover Replacement (with Knee Airbag) Instrument Panel Lower Trim Pad Cover Replacement (with Knee Airbag).

11. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement Steering Column Upper Trim Cover Replacement.

12. Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement Steering Column Lower Trim Cover Replacement.

13. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.

14. Remove the steering column. Refer to Steering Column Replacement Steering Column Replacement.




15. Disconnect the brake pedal pushrod (1) from the brake pedal.




16. Replace the click fit connector (1) between the booster pushrod and the brake pedal with new part.

17. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement Service and Repair.

18. Remove the accelerator pedal position sensor.

* For 1.4L LUJ, refer to Accelerator Pedal Position Sensor Replacement Service and Repair.

* For 1.8L LUW, refer to Accelerator Pedal Position Sensor Replacement Service and Repair.




19. If equipped, disconnect the clutch master cylinder push rod from the clutch pedal (3), using either the DT-6202-A - pliers (1) and the DT-6202-20 - adapters in conjunction with the DT-50894 - remover (2), or the DT-6202-B - pliers (1) in conjunction with the DT-50894 - remover (2).




20. Remove the clutch master cylinder nuts (1) from the pedal bracket, if equipped.




21. Remove the brake pedal bracket bolt (1) from the tie bar.

22. Separate the wiring harness from the pedal bracket.

23. Disconnect the electrical connectors.

24. Remove the brake and accelerator and clutch pedal assembly from the vehicle.

25. Transfer component parts as needed.

Installation Procedure




1. Install the brake and accelerator and clutch pedal assembly to the vehicle.

2. Install the wiring harness to the brake pedal bracket.

3. Connect the electrical connectors.

Caution: Refer to Fastener Caution Fastener Caution.

4. Install the brake pedal bracket bolts and tighten to 20 Nm (15 lb ft).

5. Connect clutch master cylinder pushrod (1) to the clutch pedal, if equipped.




6. Install the clutch master cylinder nuts (2) to the pedal bracket, if equipped and tighten to 18 Nm (13 lb ft).

7. Install the accelerator pedal position sensor.

* For 1.4L LUJ, refer to Accelerator Pedal Position Sensor Replacement Service and Repair.

* For 1.8L LUW, refer to Accelerator Pedal Position Sensor Replacement Service and Repair.

8. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement Service and Repair.




9. Connect the brake pedal pushrod (1) to the brake pedal.

10. Install the steering column. Refer to Steering Column Replacement Steering Column Replacement.

11. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.

12. Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement Steering Column Lower Trim Cover Replacement.

13. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement Steering Column Upper Trim Cover Replacement.

14. Install the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement (without Knee Airbag) Instrument Panel Lower Trim Pad Cover Replacement (without Knee Airbag)Instrument Panel Lower Trim Pad Cover Replacement (with Knee Airbag) Instrument Panel Lower Trim Pad Cover Replacement (with Knee Airbag).





Note:

* Do NOT open the hydraulic brake system.

* Second mechanic is required.

15. Pull the brake booster and the BPMV assembly forward in order to get an access to the brake pedal bracket nuts (1).

16. Install the pedal bracket nuts (1) and tighten to 20 Nm (15 lb ft).




17. Install the brake booster bolts (1) and tighten to 19 Nm (14 lb ft).




18. Install the BPMV bracket bolts (1) and tighten to 20 Nm (15 lb ft).




19. Install the BPMV bracket assembly (1).

20. Install the BPMV bracket bolts (2) and tighten to 20 Nm (15 lb ft).





Note: Do NOT disconnect the engine coolant hoses.

21. Install the radiator surge tank (1).

22. Install the radiator surge tank clip (2).

23. Install the battery tray. Refer to Battery Tray Replacement Service and Repair.

24. Install the battery. Refer to Battery Replacement Removal and Replacement.

25. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration Testing and Inspection.