Brake pedal (except for LHD MT model)
Components Removal / installation
BRAKE SYSTEM/PEDAL/BRAKE BOOSTER DEVICE
BRAKE PEDAL (EXCEPT FOR LHD MT MODEL)
EXPLODED VIEW
REMOVAL
1. Removal of instrument side panel LH (Refer to 
)
)2. Removal of instrument panel under cover SUB-ASSY No.1 (Refer to )
)3. Removal of instrument panel under cover SUB-ASSY No.2 (Refer to )
)4. Removal of knee air bag module (Refer to )
)5. Removal of stop light switch ASSY (Refer to )
)
6. Removal of stop light switch mounting adjuster
(1) Release 2 claws and remove the stop light switch mounting adjuster.
7. Removal of push rod clevis pin
(1) Remove the clips and the push rod clevis pin.
8. Removal of brake pedal support ASSY.
(1) Remove 2 bolts.
(2) Remove 4 nuts and then the brake pedal support ASSY.
DISASSEMBLY
1. Removal of brake pedal stopper.
(1) Remove the brake pedal stopper from the brake pedal.
2. Removal of brake pedal
(1) Remove the bolt and nut from the brake pedal support ASSY.
NOTE:
Hold the bolt and rotate the nut.
(2) Remove the brake pedal return spring.
(3) Remove the brake pedal shaft collar.
(4) Remove 2 brake pedal shaft bushings.
ASSEMBLY
1. Installation of brake pedal bushings
2. Installation of brake pedal
(1) Apply NIGTIGHT LYW No.2 or equivalent to the sides of brake pedal shaft collar and the brake pedal return spring.
Captions in illustration
 |
NIGTIGHT LYW No.2 or equivalent |
(2) Install the brake pedal return spring and the brake pedal shaft collar to the brake pedal.
(3) Install the brake pedal to the brake pedal support ASSY.
Captions in illustration
| *1 |
Brake pedal |
| *2 |
Brake pedal support ASSY |
(4) Install the brake pedal to the brake pedal support ASSY with bolt and nut.
Standard value:
NOTE:
Secure the bolt and tighten the nut.
Standard value:
Tightening torque=30N·m
{
306kgf·cm}
{22.1ft·lbf}
3. Installation of brake pedal stopper
(1) Install the brake pedal stopper to the brake pedal.
INSTALLATION
1. Installation of brake pedal support ASSY
(1) Temporarily install the brake pedal support ASSY with 2 bolts and 4 nuts.
(2) Tighten 4 nuts.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(3) Tighten 2 bolts.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
2. Installation of push rod clevis pin
3. Installation of stop light switch mounting adjuster
(1) Engage 2 claws, and install the stop light switch mounting adjuster.
4. Brake pedal height check/adjustment (Refer to )
)5. Brake pedal free play check (Refer to )
)6. Brake pedal clearance check (Refer to )
)7. Installation of stop light switch ASSY (Refer to )
)8. Installation of knee air bag module (Refer to )
)9. Installation of instrument panel under cover SUB-ASSY No.2 (Refer to )
)10. Installation of instrument panel under cover SUB-ASSY No.1 (Refer to )
)11. Installation of instrument side panel LH (Refer to )
)ADJUSTMENT
1. Brake pedal height check/adjustment
(1) Brake pedal height check
Captions in illustration
| *1 |
Clevis lock nut |
| *2 |
Floor mat |
| *a |
Pedal height |
(2) Brake pedal height adjustment
(a) Remove the instrument panel under cover SUB-ASSY No.1.
(b) Remove the instrument panel under cover SUB-ASSY No.2.
(c) Disconnect the connector from the stop light switch.
(d) Remove the stop light switch ASSY.
(e) Loosen the clevis lock nut and rotate the push rod clevis to adjust the pedal height.
(f) Tighten the clevis lock nut.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(g) Install the stop light switch.
(h) Connect the connector to the stop light switch.
(i) Make sure that the stop light does not illuminate with the brake pedal released.
2. Brake pedal free play check
(1) After stopping the engine, strongly depress the pedal several times to release the vacuum pressure in the brake booster.
(2) Check the brake pedal for free play.
When pushing the brake pedal with the force less than 10 N {1 kgf, 2.2 lbf}.
Captions in illustration
| *a |
Pedal free play |
| *b |
Stop light switch |
| *c |
Mat |
| *d |
Toe board |
| *e |
Brake booster operating rod |
Standard value
: 0.2-2.0 mm {0.008-0.079 in} or less
(3) If the free play is 1 mm {0.039 in} or less, check the protrusion allowance of the stop light switch ASSY shaft. (Refer to )
)3. Brake pedal clearance check
CAUTION:
Start the engine and make the vacuum pressure in the brake booster 66.7 kPa{500 mmHg} {19.69 inHg}. Then, check the brake pedal clearance.