Brake Pedal Assembly Replacement LHD

Caution: Refer to Brake Fluid Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

1. Remove the knee bolster. Refer to Knee Bolster Replacement.
2. Remove the instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.
3. Remove the instrument panel retainer. Refer to Instrument Panel Retainer Replacement.
4. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement.
5. Remove the vacuum hose and check valve from the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement.
6. Remove the brake pedal position sensor. Refer to Stop Lamp Switch Replacement.



7. Remove the brake pedal pushrod retaining clip (1), washer (2) and the brake pedal pushrod (3) from the brake pedal (4).



8. Remove the vacuum brake booster to brake pedal support bracket retaining nuts (1).

Important: From the engine compartment, pull the vacuum brake booster forward to release the four studs from the bulkhead and brake pedal support bracket.

9. Remove the vacuum brake booster from the vehicle.



10. Remove the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).

Important: Lower the brake pedal assembly rear end first to aid in removal.

11. Remove the brake pedal assembly from under the instrument panel.

Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.





Important: Raise the brake pedal assembly front end first for installation.

1. Install the brake pedal assembly.
2. Install the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).

DO NOT fully tighten at this stage.

3. Have an assistant install the vacuum brake booster from the engine compartment. Make sure the vacuum brake booster's four studs are correctly located in the bulkhead and brake pedal support bracket.



4. Install the push rod (3), washer (2) and retaining clip (1) to the brake pedal assembly (4).

Notice: Refer to Fastener Notice in the Preface section.




5. Install the vacuum brake booster to brake pedal support bracket retaining nuts (1).

Tighten
Tighten the nuts to 22 Nm. (16 lb ft)




6. Tighten the two brake pedal bracket assembly to cross car beam retaining bolts (1).

Tighten
Tighten the bolts to 23 Nm. (17 lb ft.)

7. Install the brake pedal position sensor. Refer to Stop Lamp Switch Replacement.
8. Install the vacuum hose and check valve to the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement.
9. Install the master cylinder. Refer to Master Cylinder Replacement.
10. Bleed the braking system. Refer to Hydraulic Brake System Bleeding.
11. Install the instrument panel retainer. Refer to Instrument Panel Retainer Replacement.
12. Install the instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.
13. Install the instrument panel lower trim panel assembly. Refer to Knee Bolster Replacement.
14. Road test the vehicle to inspect correct brake, stop lamp and cruise control operation.

Brake Pedal Assembly Replacement RHD

Caution: Refer to Brake Fluid Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

1. Remove the instrument panel lower trim panel assembly. Refer to Knee Bolster Replacement.
2. Remove the instrument panel lower right trim plate assembly. Refer to Instrument Panel Insulator Panel Replacement - Right Side.
3. Remove the instrument panel lower trim panel retainer. Refer to Instrument Panel Retainer Replacement.
4. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement.
5. Remove the vacuum hose and check valve from the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement.
6. Remove the brake pedal position sensor. Refer to Stop Lamp Switch Replacement.



7. Remove the brake pedal pushrod retaining clip (1), washer (2) and the brake pedal pushrod (3) from the brake pedal (4).



8. Remove the vacuum brake booster to brake pedal support bracket retaining nuts (1).

Important: From the engine compartment, pull the vacuum brake booster forward to release the four studs from the bulkhead and brake pedal support bracket.

9. Remove the vacuum brake booster from the vehicle.



10. Remove the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).

Important: Lower the brake pedal assembly rear end first to aid in removal.

11. Remove the brake pedal assembly from under the instrument panel.

Caution: Refer to Brake Fluid Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

Important: Raise the brake pedal assembly front end first to aid in installation.

1. Install the brake pedal assembly to the instrument panel crossmember.



2. Install the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).

DO NOT fully tighten at this stage.

Important: Make sure the vacuum brake booster's four studs are correctly located in the bulkhead and brake pedal support bracket.

3. With the aid of an assistant install the vacuum brake booster from the engine compartment.

Notice: Refer to Fastener Notice in the Preface section.




4. Install the vacuum brake booster to brake pedal support bracket retaining nuts (1).

Tighten
Tighten the nuts to 22 Nm (16 lb ft).




5. Install the push rod (3), washer (2) and retaining clip (1) to the brake pedal assembly (4).



6. Tighten the two brake pedal bracket assembly to cross car beam retaining bolts (1).

Tighten
Tighten the bolts to 23 Nm (17 lb ft).

7. Install the brake pedal position sensor. Refer to Stop Lamp Switch Replacement.
8. Install the vacuum hose and check valve to the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement.
9. Install the master cylinder. Refer to Master Cylinder Replacement.
10. Bleed the braking system. Refer to Hydraulic Brake System Bleeding.
11. Install the instrument panel lower trim panel retainer. Refer to Instrument Panel Insulator Panel Replacement - Right Side.
12. Install the instrument panel lower trim panel assembly. Refer to Knee Bolster Replacement.
13. Road test the vehicle to inspect correct brake, stop lamp and cruise control operation.