Brake Pedal Assy: Service and Repair

BRAKE PEDAL REMOVAL/INSTALLATION

CAUTION:
- The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch is inserted into the installation hole on the brake pedal and rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake pedal is properly installed and fully released before installing the brake switch to the pedal.
- Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again. Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or performing any procedure that changes the pedal stroke.

1. Remove the charge air cooler cover. (L3 WITH TC) Service and Repair

2. Remove the battery and battery tray. Removal and Replacement Removal and Replacement

3. Disconnect the vacuum hose from the insulator pipe as shown in the figure. (L3 WITH TC)






4. Remove the insulator. (L3 WITH TC) Service and Repair

5. Disconnect the brake pipe (master cylinder side). Service and Repair Service and Repair

6. Remove the accelerator pedal. Service and Repair Service and Repair

7. Remove in the order indicated in the table.

8. Install in the reverse order of removal.

9. Add brake fluid, bleed the brakes, and inspect for leakage after the installation has been completed. Service and Repair










Brake Pedal Removal Note

1. Remove the brake pedal installation bolts and nuts.

2. Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.

3. Remove the brake pedal.

Joint Pin Installation Note

1. Install the new joint pin by aligning the pin holes of the brake pedal and power brake unit fork.

2. Verify that the joint pin touches the power brake unit fork completely.






Brake Switch Installation Note

1. Inspect the brake pedal. Testing and Inspection

2. With the brake pedal fully released, insert a new brake switch into the installation hole on the brake pedal.

3. Secure the brake switch by turning it counterclockwise 45°.