BRAKE PEDAL (for RHD) INSTALLATION


  1. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY


    1. A0041IC

      Install the nut to the brake pedal support assembly.

    2. A004035

      Install the brake pedal support assembly with the 4 nuts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    3. A00427N

      Engage the 2 clamps.

    4. A00421EE01
      Text in Illustration
      *1 Bolt Size

      Install the brake pedal support assembly to the instrument panel reinforcement with the bolt.

      Bolt Type Bolt Size
      Bolt A 14 mm (0.551 in.)
      Bolt B 12 mm (0.472 in.)
      Torque:
      for Bolt A
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }
      for Bolt B
      24 N*m  { 241 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Two types of bolts each with a different torque specification can be used.

  2. INSTALL PUSH ROD PIN


    1. Apply lithium soap base glycol grease to the push rod pin and installation hole of the brake pedal support assembly.

    2. A0040JL

      Install the push rod pin and a new clip to connect the push rod clevis to the brake pedal support assembly.

  3. INSTALL BRAKE PEDAL RETURN SPRING


    1. A0042X1

      Install the brake pedal return spring to the brake pedal support assembly and push rod pin.

  4. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER

  5. INSTALL STOP LIGHT SWITCH ASSEMBLY


    1. A0042RM

      Insert the stop light switch assembly until the threaded sleeve hits the pedal.

      Note

      When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

    2. A00439XE01

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

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf, or less }

      Note

      When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

    3. Connect the connector.

    4. Check the protrusion of the plunger.

      Protrusion of Plunger
      Area Measurement
      a 0.5 to 2.6 mm (0.0197 to 0.102 in.)

      If the protrusion is not as specified, recheck switch installation and inspect brake pedal adjustment if necessary Click here for LHD or Click here for RHD).

      Note

      Do not depress or support the brake pedal.

  6. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY

    Note


    • Do not drop the brake pedal stroke sensor assembly.

    • If the brake pedal stroke sensor assembly has been dropped, replace the brake pedal stroke sensor assembly with a new one.


    1. When installing a new brake pedal stroke sensor assembly:

      Note

      Do not break the brake pedal stroke sensor assembly lever set pin before installing the brake pedal stroke sensor assembly with the 2 nuts.


      1. A0043HPE05
        Text in Illustration
        *a Brake Pedal Groove
        *b Brake Pedal Stroke Sensor Assembly Lever

        Install a new brake pedal stroke sensor assembly with the 2 nuts.

        Torque:
        7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

        Note


        • Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.

        • Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor assembly.

        • Check that the tip of the brake pedal stroke sensor assembly lever is protruding from the brake pedal groove.

        • Tighten the 2 nuts in the order shown in the illustration.

      2. Connect the connector to the brake pedal stroke sensor assembly.

      3. Firmly depress the brake pedal and break the brake pedal stroke sensor assembly lever set pin.

      4. Remove the broken brake pedal stroke sensor assembly lever set pin.

    2. When reusing the brake pedal stroke sensor assembly:


      1. A0043HPE06
        Text in Illustration
        *a Brake Pedal Groove
        *b Brake Pedal Stroke Sensor Assembly Lever

        Temporarily install the brake pedal stroke sensor assembly with the 2 nuts.

        Note


        • Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.

        • Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor assembly.

      2. Connect the connector to the brake pedal stroke sensor assembly.

  7. INSTALL ECU INTEGRATION BOX RH


    1. A0043G9

      Install the ECU integration box RH with the bolt and nut.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    2. Connect the connectors to the ECU integration box RH.

  8. INSTALL UPPER INSTRUMENT PANEL ASSEMBLY

    Click here

  9. INSPECT AND ADJUST BRAKE PEDAL

    Click here

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


    1. Connect each connector.

    2. Engage the guide and 2 claws.

    3. Install the No. 1 instrument panel under cover sub-assembly with the screw <D>.

  11. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE

    Click here