BRAKE PEDAL INSTALLATION


  1. INSTALL BRAKE PEDAL PAD


    1. Install the brake pedal pad onto the brake pedal sub-assembly.

  2. INSTALL STOP LIGHT SWITCH CUSHION


    1. Install the stop light switch cushion onto the brake pedal sub-assembly.

  3. INSTALL BRAKE PEDAL BUSH


    1. A01CHDTE01
      Text in Illustration
      *1 Lithium Soap Base Glycol Grease

      Apply lithium soap base glycol grease to 2 new brake pedal bushes and the brake pedal shaft collar.

    2. Install the 2 brake pedal bushes and brake pedal shaft collar onto the brake pedal sub-assembly.

  4. INSTALL BRAKE PEDAL RETURN SPRING


    1. Apply lithium soap base glycol grease to the contact points of the brake pedal return spring, brake pedal sub-assembly and pedal bracket assembly.

    2. Install the brake pedal return spring onto the brake pedal sub-assembly.

  5. INSTALL BRAKE PEDAL SUB-ASSEMBLY


    1. Install the brake pedal sub-assembly onto the pedal bracket assembly with the bolt and nut.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  6. INSTALL PUSH ROD PIN


    1. A01CIIAE01
      Text in Illustration
      *1 Lithium Soap Base Glycol Grease

      Apply lithium soap base glycol grease to the push rod pin.

    2. Install the push rod pin with a new clip.

  7. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER


    1. Attach the 2 claws to install a new stop light switch mounting adjuster.

  8. INSTALL STOP LIGHT SWITCH ASSEMBLY


    1. A01CHBE

      Make a quarter turn clockwise to install the stop light switch onto the pedal bracket assembly.

      Tech Tips

      Adjust the stop light switch clearance after adjusting the brake pedal height.

    2. Connect the connector to the stop light switch.

  9. INSTALL PEDAL BRACKET ASSEMBLY


    1. Install the pedal bracket assembly with the 2 bolts and the 2 nuts.

      Torque:
      Bolt
      28 N*m  { 286 kgf*cm, 20 ft.*lbf }
      Nut
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note

      Do not damage the brake lines or fuel lines.

    2. Connect the connectors and clamps to the pedal bracket assembly.

    3. Connect the vacuum hose to the booster vacuum tube with the clip.

    4. Install the brake tube way with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    5. Using a 12 mm union nut wrench, install the 2 brake tubes onto the brake tube way.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  10. CONNECT MASTER CYLINDER TO TUBE CONNECTOR TUBE


    1. Using a 12 mm union nut wrench, install the master cylinder to tube connector tube onto the brake tube way.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  11. INSTALL INSTRUMENT PANEL REINFORCEMENT


    1. Temporarily tighten the instrument panel reinforcement with the 10 bolts and 2 nuts.

    2. Tighten the 6 bolts A and the 2 nuts.

      A01CIRJE01
    3. A01CILQE01

      Tighten the 12 bolts in the order shown in the illustration.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    4. Connect the connectors and attach the 4 clamps, then install the wire harness.

      A01CHLP

    5. Install the wire harness protector with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  12. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Install the brake master cylinder reservoir assembly with the bolt.

  13. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. A01CHEXE01

      Install the No. 1 instrument panel brace sub-assembly with the 3 bolts.

      Torque:
      Bolt A
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  14. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY


    1. Attach the 2 claws to install No. 4 air duct sub-assembly.

    2. Install the 2 clips.

  15. INSTALL ECU BRACKET


    1. Install the ECU bracket with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  16. INSTALL ECU BRACKET


    1. Install the ECU bracket with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  17. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  18. INSTALL INSTRUMENT PANEL ASSEMBLY

    Click here

  19. INSTALL WINDSHIELD WIPER LINK ASSEMBLY

    Click here

  20. REMOVE OIL RESERVOIR TANK COVER LH


    1. A01CIYJ

      Disengage the 4 claws and 3 guides and remove the oil reservoir tank cover LH.

  21. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH


    1. A01CHYB

      Detach the 5 clips and remove the lower instrument panel finish panel sub-assembly.

    2. Disconnect each connector.

  22. FILL RESERVOIR WITH BRAKE FLUID


    1. A01CHDW

      Fill the reservoir with brake fluid.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

      Note

      Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

  23. BLEED BRAKE LINE

    A01CIA0

    Note


    • Make sure the vehicle is secured in place and cannot move.

    • Make sure the ignition switch is off before bleeding the brake system.


    1. Connect the vinyl tube to the bleeder plug.

    2. Depress the brake pedal 3 times, and then hold down the brake pedal. (Procedure 1)

    3. Loosen the bleeder plug at least 90° so that brake fluid and air begin to come out, and then tighten the bleeder plug approximately 2 seconds after opening it. (Procedure 2)

    4. Wait 3 seconds after Procedure 2, and then begin depressing the brake pedal again. Repeat Procedures 1 and 2, 10 times or more. (Procedure 3)

      Note

      Even if air does not come out, repeat the procedures 10 times or more.

    5. Repeat Procedure 1 through Procedure 3 above, twice for each wheel, in the following order: Left Front → Left Rear → Right Rear → Right Front → Left Front → Left Rear → Right Rear → Right Front.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  24. BLEED CLUTCH LINE

    Tech Tips

    See Pub. No. RM1008E, page 42-2.

  25. INSPECT FOR BRAKE FLUID LEAK

  26. INSPECT BRAKE PEDAL RESERVE DISTANCE

    Click here

    Note

    If the pedal reserve is low, there may be air remaining in the brake system, so perform a driving test and bleed the brake system again.

  27. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT

    Click here

  28. CHECK FLUID LEVEL IN RESERVOIR

    A01CHDW

    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  29. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH


    1. Connect each connector.

    2. Attach the 5 clips to install the lower instrument panel finish panel sub-assembly.

  30. INSTALL OIL RESERVOIR TANK COVER LH


    1. Engage the 4 claws and 3 guides to install the oil reservoir tank cover LH.