BRAKE PEDAL INSTALLATION

Tech Tips


  • Use the same procedure for the RHD and LHD vehicles.

  • The procedure listed below is for the LHD vehicles.


  1. INSTALL BRAKE PEDAL PAD


    1. Install the brake pedal pad to the brake pedal support assembly.

  2. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY


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

      Note

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


      1. A01FT10E01
        Text in Illustration
        *1 Pin
        *2 Lever
        *a Groove

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

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 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.

      2. Strongly depress the brake pedal to break the brake pedal stroke sensor assembly lever set pin.

      3. Remove the broken lever set pin.

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

    2. When reusing the brake pedal stroke sensor assembly:


      1. A01FROKE01
        Text in Illustration
        *1 Lever
        *a Groove

        Temporarily install the brake pedal stroke sensor assembly to the brake pedal support 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.

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

        Tech Tips

        Tighten the 2 nuts after adjusting the installation position.

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

  3. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY


    1. Temporarily install the brake pedal support reinforcement set bolt.

    2. Install the brake master cylinder sub-assembly Click here.

    3. Tighten the brake pedal support assembly with the 4 nuts.

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

    4. Tighten the brake pedal support reinforcement set bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  4. CONNECT PUSH ROD PIN


    1. A01FTG4E01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the push rod pin.

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

      Note

      After installation, check that the pedal operates smoothly.

  5. INSTALL BRAKE PEDAL RETURN SPRING


    1. Install the brake pedal return spring to the brake pedal support assembly.

  6. INSTALL STOP LIGHT SWITCH ASSEMBLY


    1. Temporarily install the stop light switch assembly to the brake pedal support with the lock nut.

      Tech Tips

      The lock nut is tightened when inspecting and adjusting the brake pedal height.

    2. Attach the 2 clamps to the brake pedal support.

    3. Connect the 2 connectors.

  7. CHECK AND ADJUST BRAKE PEDAL

    Click here

  8. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

    Click here

  9. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  10. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH


    1. Install the luggage compartment trim cover LH.

  11. INSTALL LUGGAGE COMPARTMENT FLOOR MAT


    1. Install the luggage compartment floor mat.

  12. CHECK SRS WARNING LIGHT

    Click here

  13. BLEED BRAKE SYSTEM

    CAUTION:

    If the brake fluid is replaced without using the GTS, the procedure will be incomplete which could lead to problems or accidents. Always use the GTS when performing fluid replacement.


    1. Bleed air from the brake system.


      1. A01FSJ7

        Remove the 2 ABS motor relays.

        Tech Tips

        If the ABS motor relays are already removed, this procedure is unnecessary.

      2. With the power switch off, connect the GTS to the DLC3.

      3. Remove the brake master cylinder reservoir filler cap assembly.

      4. Adjust the brake fluid amount so that the brake fluid level is at the MIN level of the brake fluid reservoir.

      5. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / Zero Down.

        Tech Tips

        Using the GTS to perform zero down causes the pressurized fluid in the accumulator to be returned to the brake fluid in the accumulator to be returned to the brake fluid reservoir.

      6. Confirm the sounds of the buzzer and turn the power switch off.

      7. Add brake fluid so that the fluid level is between the MIN and MAX lines of the brake fluid reservoir.

      8. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Invalid.

      9. Bleed air from the No. 1 brake actuator tube.

        Tech Tips

        If the No. 1 brake actuator tube (between the master cylinder and brake actuator) is disconnected, bleed air using the following procedure.


        1. Add brake fluid so that the fluid level is between the MIN and MAX lines of the brake fluid reservoir.

        2. Remove the cover from the top of the brake master cylinder reservoir filler cap assembly.

        3. Set the vacuum pump to pressurized state (discharge) and install the small diameter attachment to the hose.

        4. A01FUGRE01

          Insert the small diameter attachment into the air hole of the reservoir cap to install it.

          Text in Illustration
          *1 Vacuum Pump
          *2 Small Diameter Attachment

        5. Connect a vinyl tube to the bleeder plug of the brake actuator.

        6. Loosen the bleeder plug of the brake actuator.

        7. Using the vacuum pump, increase the pressure inside the brake fluid reservoir.

        8. Drain the air and brake fluid inside the tube and tighten the bleeder plug.

        9. With the bleeder plug tightened, maintain the pressure in the brake fluid reservoir at 0.08 MPa, and then loosen the bleeder plug to bleed air.

          NOTICE
          Perform this procedure 5 times or more.

        10. Tighten the bleeder plug all the air between the brake fluid reservoir and brake actuator is bled.

          Torque
          8.3 N*m (85 kgf*cm, 73 in.*lbf)

        11. Release the pressure in the brake fluid reservoir and remove the vinyl tube, vacuum pump and small diameter attachment.

        12. Install the cover on the top of the brake master cylinder reservoir filler cap assembly.

      10. Repeatedly depress the brake pedal to bleed the air from the bleeder plug of the front disc brake cylinder RH.

        Tech Tips

        Repeatedly depress the brake pedal 30 times or more, as air often remains inside the brake stroke simulator cylinder.

        Note

        Add fluid so that the fluid level does not drop below the MIN line on the brake fluid reservoir.

      11. After bleeding the air, depress and hold the brake pedal, and tighten the bleeder plug.

        Torque:
        11 N*m  { 110 kgf*cm, 8 ft.*lbf }

      12. In the same way as the RH side, bleed air from the bleeder plug of the front disc brake cylinder LH.

      13. Follow the GTS screen, to end ECB (Electronically Controlled Brake system) Invalid.

      14. Install the 2 ABS motor relays with the power switch off.

      15. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / ECB (Electronically controlled Brake system) Invalid.

      16. While depressing the brake pedal, loosen the bleeder plug of the rear disc brake cylinder LH. While the pump motor and solenoid are operating, bleed the air.

        Note

        Add fluid so that the fluid level does not drop below the MIN line on the brake fluid reservoir.

      17. After bleeding the air, tighten the bleeder plug and release the brake pedal.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      18. In the same way as the LH side, bleed air from the bleeder plug of the rear disc brake cylinder RH.

      19. Follow the GTS screen, to end ECB (Electronically Controlled Brake system) Invalid.

      20. Adjust the brake fluid amount so that the brake fluid level is at the MIN level of the brake fluid reservoir.

      21. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically controlled Brake system) Utility / Zero Down.

      22. Confirm the sounds of the buzzer and turn the power switch off.

      23. Turn the power switch on (IG), and then after confirming that the pump motor stops operating, perform zero down again.

        Tech Tips

        The operation of the pump motor can be confirmed by listening to the operating sound.

      24. In order to circulate the fluid inside the accumulator, perform "Zero Down" a total of 5 times.

    2. Clear DTCs Click here.

    3. Turn the GTS off and turn the power switch off.

    4. Check for brake fluid leaks.

    5. Inspect and adjust the brake fluid level in the reservoir Click here.