BRAKE PEDAL (for LHD) INSTALLATION


  1. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY


    1. A01ES67

      Install the brake pedal support assembly with the 4 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }
    2. A01EN62

      Install the brake pedal support reinforcement set bolt.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
    3. A01EO0K

      Tighten the bolt and nut.

      Torque:
      23 N*m  { 239 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Hold the bolt in place and tighten the nut.

  2. INSTALL PUSH ROD PIN


    1. Apply a light coat of lithium soap base glycol grease to the inner surface of the hole on the brake pedal lever.

    2. A01EOJH

      Set the master cylinder push rod clevis in place, insert the push rod pin from the outside of the vehicle and then install a new clip.

  3. INSTALL STOP LIGHT SWITCH ASSEMBLY


    1. Install the stop light switch Click here.

    2. Connect the stop light switch connector.

  4. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY


    1. A01ENCE

      Connect the connector.

      Note

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

    2. Install the driver side knee airbag with the 5 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL

    A01EN2R

    1. Connect the connectors.

    2. Attach the 2 claws to install the sensor.

    3. A01EQEE

      Attach the 2 claws to connect the 2 control cables.

    4. A01EQBC

      Attach the 16 claws to install the finish panel.

    5. A01EOJD

      Install the 2 bolts.

    6. A01ENQK

      Attach the 2 claws to close the hole cover.

  6. INSTALL COWL SIDE TRIM BOARD LH


    1. A01EQ1Q

      Attach the 2 clips to install the trim board.

    2. Install the cap nut.

  7. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. A01EQBL

      Connect the connectors.

    2. Attach the 3 claws to install the under cover.

    3. Install the 2 screws.

  8. INSTALL FRONT DOOR SCUFF PLATE LH

    A01EQ14

    1. w/o Illumination:


      1. Attach the 7 claws and 4 clips to install the scuff plate.

    2. A01EOWQ

      w/ Illumination:


      1. Connect the connector.

      2. Attach the 7 claws and 4 clips to install the scuff plate.

  9. CHECK BRAKE PEDAL HEIGHT


    1. A01ER98E01

      Check the brake pedal height.

      Standard Pedal Height from No. 2 Dash Panel Insulator Pad
      147.1 to 157.1 mm (5.80 to 6.18 in.)

      Note

      Do not adjust the pedal height. Doing so by changing the push rod length will structurally change the pedal ratio.

      If the pedal height is incorrect, adjust the rod operating adapter length.

    2. A01EQ1VE01

      Adjust the rod operating adapter length.


      1. Remove the clip and clevis pin.

      2. Loosen the clevis lock nut.

      3. Adjust the rod operating adapter length by turning the pedal push rod clevis.

        Standard Rod Operating Adapter Length "A"
        201.7 to 202.7 mm (7.94 to 7.98 in.)

      4. Tighten the clevis lock nut.

        Torque:
        26 N*m  { 260 kgf*cm, 19 ft.*lbf }

      5. Set the master cylinder push rod clevis in place, insert the push rod pin from the outside of the vehicle and then install a new clip.

        If the pedal height is incorrect even if the rod operating adapter is adjusted, check that there is no damage to the brake pedal, brake pedal lever, brake pedal support and dash panel.


        • Even if there is damage, there is no problem if the reserve distance is within the standard value.

        • If necessary, replace any damaged parts.

  10. CHECK PEDAL FREE PLAY


    1. A01EOIYE01

      Push in the pedal until resistance is felt. Measure the free play as shown in the illustration.

      Standard Pedal Free Play
      1 to 6 mm (0.0394 to 0.236 in.)

  11. CHECK PEDAL RESERVE DISTANCE


    1. A01ERO6E01

      Release the parking brake lever. With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.

      Standard Pedal Reserve Distance from No. 2 Dash Panel Insulator Pad at 490 N (50 kgf, 110.2 lbf)
      More than 67 mm (2.64 in.)

      If incorrect, troubleshoot the brake system.

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.