BRAKE PEDAL > INSTALLATION

for Preparation Click here

1. Install the brake pedal assembly with the 4 nuts.
   

   Torque:

   12.7 N*m{ 130 kgf*cm , 9 ft.*lbf }

2. Install the brake pedal assembly with the bolt.
   

   Torque:

   44 N*m{ 449 kgf*cm , 33 ft.*lbf }

3. Connect the stop light switch connector and pedal stroke sensor connector.
   

1. Apply lithium soap base glycol grease to the clevis pin.
   

2. Install the clevis pin and a new clip.
   

NOTICE:

Perform check and adjustment with the rug removed.

1. Check the brake pedal height.
   

   Pedal height from the silencer pad:

   LHD:

   144.7 to 154.7 mm (5.697 to 6.090 in.)
   

   RHD:

   154.9 to 164.9 mm (6.098 to 6.492 in.)
   

2. Adjust the brake pedal height.
   
   

   1. Disconnect the connector from the stop light switch assembly.
      

   2. Loosen the stop light switch lock nut. Turn the switch in order to give the pedal some free play.
      

   3. Loosen the clevis lock nut.
      

   4. Adjust the pedal height by turning the pedal push rod.
      

      Pedal height from the silencer pad:

      LHD:

      144.7 to 154.7 mm (5.697 to 6.090 in.)
      

      RHD:

      154.9 to 164.9 mm (6.098 to 6.492 in.)
      

   5. Tighten the clevis lock nut.
      

      Torque:

      26 N*m{ 265 kgf*cm , 19 ft.*lbf }

   6. Turn the stop light switch assembly so that the clearance between the nut end and the stop light switch cushion is between 0.5 and 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.
      

      Torque:

      16.7 N*m{ 170 kgf*cm , 12 ft.*lbf }

   7. Connect the connector to the stop light switch assembly.
      

1. Connect the intelligent tester to the DLC3.
   

2. Loosen the 2 bolts.
   

3. Turn the ignition switch to the ON position. Reading the stroke sensor 1 value shown on the intelligent tester screen, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
   

   Standard voltage:

   0.8 to 1.2 V
   

4. Tighten the 2 bolts.
   

   Torque:

   9.3 N*m{ 95 kgf*cm , 82 in.*lbf }

   NOTICE:

   Do not depress the brake pedal after turning the ignition switch to the ON position.

5. Perform system initialization. (Click here)
   

1. Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.
   

   Pedal free play:

   1 to 2 mm (0.039 to 0.079 in.)
   

   
   

   1. If the pedal free play is 1.0 mm (0.039 in.) or less, check the protrusion of the stop light switch assembly shaft.
      

      Protrusion of the stop light switch assembly shaft:

      0.5 to 2.4 mm (0.020 to 0.095 in.)
      

      HINT:

      1. Adjust if the protrusion is off the specified value.
         
      2. If the protrusion is within the specified value, it is normal though brake pedal free play is 1.0 mm (0.039 in.) or less.
         

1. Release the parking brake pedal.
   

2. With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.
   

   Pedal reserve distance from the dash panel at 490 N (50 kgf, 110 lbf):

   LHD:

   More than 90 mm (3.54 in.)
   

   RHD:

   More than 100 mm (3.94 in.)
   

1. Install the driver side knee airbag assembly with the 4 bolts.
   

   Torque:

   7.6 N*m{ 78 kgf*cm , 68 in.*lbf }

2. Connect the connector to the driver side knee airbag assembly.
   

   NOTICE:

   When handling the airbag connector, take care not to damage the airbag wire harness.

1. Connect the connectors.
   

2. Engage the 5 claws and the 4 clips.
   

3. Connect the hood lock control cable assembly.
   

4. Install the bolt <A>, the screw <C>, and the instrument panel finish panel sub-assembly lower.