BRAKE PEDAL (w/ VSC) INSTALLATION


  1. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY


    1. A01DVHU

      Install the support with the 4 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }
    2. A01DY8Q

      for 1KD-FTV and 2KD-FTV with Manual Transmission:

      Attach the connector clamp and clamp to the brake pedal support sub-assembly.

    3. A01DZGBE01

      Install the bolt to the support.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  2. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A01DXHTE01

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

    2. Connect the push rod clevis to the brake pedal.

    3. Install the clevis pin and a new clip.

      Note

      The clip must be installed as shown in the illustration.

    4. Install the return spring.

  3. CHECK AND ADJUST BRAKE PEDAL HEIGHT

    A01E0GXE01

    1. Check the pedal height.

      Pedal height from dash panel
      Item Specified Condition
      LHD (M/T) 152.9 to 162.9 mm (6.020 to 6.413 in.)
      LHD (A/T) 154.1 to 164.1 mm (6.067 to 6.461 in.)
      RHD (M/T) 156.9 to 166.9 mm (6.177 to 6.571 in.)
      RHD (A/T) 158.1 to 168.1 mm (6.224 to 6.618 in.)

    2. Adjust the pedal height.


      1. Disconnect the connector from the stop light switch.

      2. Remove the switch.

      3. Loosen the push rod clevis lock nut.

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

      5. Tighten the lock nut.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      6. A01DYMCE04

        Insert the switch into the adjuster until it slightly touches the pedal.

        Note

        Do not depress the pedal.

      7. A01E1P4E03

        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
        1.5 to 2.5 mm (0.0591 to 0.0984 in.)

  4. CHECK BRAKE PEDAL FREE PLAY

    A01E31ZE02

    1. Stop the engine. Depress the pedal several times until there is no vacuum in the booster. Then release the pedal.

    2. Depress the pedal until resistance is felt.

    3. Check the pedal free play by measuring the distance between the position in the previous step and the pedal's released position.

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

      If the free play is not as specified, check the switch clearance in the next step.

      If the free play is as specified, proceed to the "check brake pedal reserve distance" procedure.

    4. Check the switch clearance.

      Stop light switch clearance
      1.5 to 2.5 mm (0.0591 to 0.0984 in.)

      If the clearance is not as specified, adjust the clearance and recheck the pedal free play.

      If the clearance is as specified, troubleshoot the brake system and proceed to the "check brake pedal reserve distance" procedure.

  5. CHECK BRAKE PEDAL RESERVE DISTANCE

    A01DVJIE08

    1. Release the parking brake lever. Start the engine.

    2. Depress the pedal and check the pedal reserve distance.


      1. Depress the pedal with a force of 490 N (50 kgf, 110 lbf).

      2. Measure the distance between the pedal and dash panel shown in the illustration.

        Pedal reserve distance
        Model Specified Condition
        for LHD 85.0 mm (3.347 in.)
        for RHD 89.0 mm (3.504 in.)

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

  6. INSTALL COMBINATION METER ASSEMBLY


    1. Install the combination meter assembly Click here.

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  8. CHECK SRS WARNING LIGHT


    1. w/ Airbag System:

      Check the SRS warning light Click here.