BRAKE PEDAL INSTALLATION


  1. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY


    1. A01ISXK

      Install the nut to the brake pedal support sub-assembly.

    2. A01IQO6E04
      Text in Illustration
      *A for LHD
      *B for RHD

      Install the brake pedal support sub-assembly with the 4 nuts. Tighten the 4 nuts uniformly in alphabetical order.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    3. A01ISZ5E02
      Text in Illustration
      *A for LHD
      *B for RHD

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

      Torque:
      24 N*m  { 241 kgf*cm, 17 ft.*lbf }

  2. INSTALL STOP LIGHT SWITCH ASSEMBLY


    1. Install the stop light switch assembly Click here.

  3. INSTALL PUSH ROD PIN


    1. A01ISZOE03
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Lithium soap base glycol grease

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

    2. Connect the brake master cylinder push rod to the brake pedal with the push rod pin and install a new clip as shown in the illustration.

  4. INSTALL BRAKE PEDAL RETURN SPRING


    1. A01IRMFE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Install the brake pedal return spring between the brake pedal support sub-assembly and brake master cylinder push rod clevis.

  5. INSPECT AND ADJUST BRAKE PEDAL HEIGHT


    1. A01IT94E03
      Text in Illustration
      *1 Stop Light Switch
      *2 Clevis Lock Nut
      *3 Floor Panel
      *a Pedal Height

      Check the brake pedal height.

      Pedal Height from Floor Panel
      for LHD
      Item Specified Condition
      for Automatic Transaxle and CVT 148.5 to 158.5 mm (5.85 to 6.24 in.)
      for Manual Transaxle
      for RHD
      Item Specified Condition
      for Automatic Transaxle and CVT 131.5 to 141.5 mm (5.18 to 5.57 in.)
      for Manual Transaxle 132.2 to 142.2 mm (5.20 to 5.60 in.)

    2. Adjust the brake pedal height.


      1. Disconnect the stop light switch connector.

      2. Remove the stop light switch assembly.

      3. Loosen the push rod clevis lock nut.

      4. Adjust the brake pedal height by turning the push rod.

      5. Tighten the push rod clevis lock nut.

        Torque:
        22 N*m  { 224 kgf*cm, 16 ft.*lbf }

      6. Insert the stop light switch into the adjuster mounting until the switch body touches the brake pedal.

        Note

        Do not depress the brake pedal.

      7. Turn the switch a quarter turn clockwise.

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

        Note

        Do not depress the pedal.

      8. Connect the connector to the switch.

      9. Check the switch clearance.

        Stop light switch clearance
        0.5 to 2.6 mm (0.0197 to 0.102 in.)

  6. INSPECT BRAKE PEDAL FREE PLAY


    1. Stop the engine. Depress the brake pedal several times until no vacuum is left in the brake booster. Release the brake pedal.

    2. A01IUSAE05
      Text in Illustration
      *a Pedal Free Play

      Depress the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.

      Pedal free play
      1.0 to 6.0 mm (0.0394 to 0.236 in.)

      If the pedal free play is not as specified, check the stop light switch clearance.

  7. INSPECT BRAKE PEDAL RESERVE DISTANCE

    Tech Tips

    Measure the distance from the same point used for the brake pedal height inspection.


    1. Release the parking brake.

    2. With the engine running, depress the brake pedal and measure the pedal reserve distance.

      Pedal Reserve Distance from the Floor Panel at 294 N (30 kgf, 66 lbf)
      Model Specified Condition
      for LHD (except 2AD-FHV) 75 mm (2.95 in.)
      for LHD (2AD-FHV) 80 mm (3.15 in.)
      for RHD 70 mm (2.76 in.)

      If the distance is not as specified, troubleshoot the brake system Click here.

  8. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY


    1. Install the lower No. 1 instrument panel airbag assembly Click here.

  9. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the upper instrument panel sub-assembly Click here.