Brake Pedal Assy: Service and Repair

BRAKE PEDAL

COMPONENTS:

REMOVAL
1. PRECAUTION
2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER LH
4. REMOVE ENGINE ROOM SIDE COVER RH
5. REMOVE FRONT UPPER FENDER PROTECTOR LH
6. REMOVE FRONT UPPER FENDER PROTECTOR RH
7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH
8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH
9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE WINDSHIELD WIPER ARMAND BLADE ASSEMBLY LH
11. REMOVE WINDSHIELD WIPER ARMAND BLADE ASSEMBLY RH
12. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
13. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait for 90 seconds after disconnecting the terminal to prevent airbag deployment.

14. SEPARATE NO. 3 ENGINE ROOM RELAY BLOCK
15. REMOVE FRONT WHEEL
16. DRAIN BRAKE FLUID

NOTICE: If brake fluid leaks onto any painted surface, wash off or remove the brake fluid completely.

17. REMOVE FRONT DOOR SCUFF PLATE LH (w/o Illumination)
18. REMOVE FRONT DOOR SCUFF PLATE LH (w/Illumination)
19. REMOVE FRONT DOOR OPENING TRIM COVER LH
20. REMOVE INSTRUMENT SIDE PANEL LH
21. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
22. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
23. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
24. REMOVE BRAKE ACTUATOR ASSEMBLY WITH BRACKET
25. SEPARATE CLUTCH RESERVOIR HOSE (for Manual Transmission)
26. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
27. REMOVE BRAKE PEDAL RETURN SPRING
28. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
29. REMOVE BRAKE BOOSTER ASSEMBLY
30. REMOVE BRAKE BOOSTER GASKET
a. Remove the brake booster gasket.
31. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY

a. Disconnect the 2 connectors.

b. Remove the bolt and brake pedal support assembly.
32. REMOVE STOP LIGHT SWITCH ASSEMBLY
a. Loosen the lock nut and remove the stop light switch assembly.
33. REMOVE CUSHION
a. Remove the cushion.
34. REMOVE BRAKE PEDAL PAD
a. Remove the brake pedal pad.

ADJUSTMENT
1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT
a. Check the brake pedal height.
Pedal height from asphalt sheet (MT): 146.6 to 156.6 mm (5.772 to 6.165 inch)
Pedal height from asphalt sheet (AT for 2WD): 151.8 to 161.8 mm (5.976 to 6.370 inch)
Pedal height from asphalt sheet (AT for 4WD): 1 65.3 to 175.3 mm (6.508 to 6.902 inch)
b. Adjust brake pedal height.

1. Disconnect the connector from the stop light switch assembly.
2. Loosen the stop light switch lock nut. Turn the switch in order to give the pedal some freeplay.
3. Remove the brake booster assembly.

4. Loosen the push rod lock nut, turn the push rod clevis and adjust dimension A shown in the illustration.
Dimension A: 146.2 to 147.2 mm (5.756 to 5.795 inch)
5. Tighten the push rod lock nut.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
6. Install the brake booster assembly.

7. Turn the stop light switch assembly so that the clearance between the switch and the area where the pedal makes contact is between 0.5 and 2.4 mm (0.020 to 0.095 inch). Tighten the lock nut.
Torque: 17 Nm (170 kgf-cm, 12 ft. lbs.)
8. Connect the connector to the stop light switch assembly
2. INSPECT PEDAL FREE PLAY
a. Stop the engine and depress the brake pedal several times until no vacuum is left in the booster.

b. Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.
Pedal free play: 1.0 to 2.0 mm (0.039 to 0.079 inch)
If the pedal free play is 1 mm (0.04 inch) or less, check the protrusion of the stop light switch assembly shaft.
Protrusion of the stop light switch assembly shaft: 0.5 to 2.4 mm (0.020 to 0.095 inch)
If the protrusion is not within the specified range, adjust it.
If the protrusion is within the specified range, it is normal though brake pedal free play is 1.0 mm (0.039 inch) or less.

3. INSPECT PEDAL RESERVE DISTANCE
a. Release the parking brake pedal.
b. With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbs.)
2GR-FSE, 6AT: More than 105 mm (4.13 inch)
4GR-FSE, 6AT: More than 108 mm (4.25 inch)
4GR-FSE, 6MT: More than 104 mm (4.09 inch)
If incorrect, troubleshoot the brake system.

INSTALLATION
1. INSTALL BRAKE PEDAL PAD
2. INSTALL CUSHION
3. INSTALL STOP LIGHT SWITCH ASSEMBLY
a. Temporarily install the stop light switch assembly with the lock nut.
b. Fully tighten the stop light switch assembly with the lock nut after inspecting and adjusting brake pedal height.
4. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY

a. Install the brake pedal support assembly with the bolt.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)

b. Engage the wire harness clamp.
c. Connect the 2 connectors.
5. INSTALL BRAKE BOOSTER GASKET
6. INSTALL BRAKE BOOSTER ASSEMBLY
7. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
8. INSTALL BRAKE PEDAL RETURN SPRING
9. INSTALL BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY
10. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission)
11. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET
12. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK
13. CONNECT BATTERY NEGATIVE TERMINAL
14. ADD BRAKE FLUID
15. BLEED MASTER CYLINDER
16. BLEED BRAKE LINE
17. BLEED BRAKE ACTUATOR ASSEMBLY
18. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)
19. INSPECT FLUID LEVEL IN RESERVOIR
20. INSPECT FOR BRAKE FLUID LEAKAGE
21. INSPECT AND ADJUST BRAKE PEDAL HEIGHT
22. INSPECT PEDAL FREE PLAY
23. INSPECT PEDAL RESERVE DISTANCE
24. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait for 90 seconds after disconnecting the terminal to prevent airbag deployment.

25. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
26. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
27. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
28. INSTALL INSTRUMENT SIDE PANEL LH
29. INSTALL FRONT DOOR OPENING TRIM COVER LH
30. INSTALL FRONT DOOR SCUFF PLATE LH (w/Illumination)
31. INSTALL FRONT DOOR SCUFF PLATE LH (w/o/Illumination)
32. INSTALL FRONT WHEEL
33. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
34. INSTALL WINDSHIELD WIPER ARMAND BLADE ASSEMBLY RH
35. INSTALL WINDSHIELD WIPER ARMAND BLADE ASSEMBLY LH
36. INSTALL FRONT WIPER ARM HEAD CAP
37. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
38. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
39. INSTALL FRONT UPPER FENDER PROTECTOR RH
40. INSTALL FRONT UPPER FENDER PROTECTOR LH
41. INSTALL ENGINE ROOM SIDE COVER RH
42. INSTALL ENGINE ROOM SIDE COVER LH
43. INSTALL COOL AIR INTAKE DUCT SEAL
44. CONNECT BATTERY NEGATIVE TERMINAL
45. CHECK AND CLEAR DTC
46. INSPECT VSC SENSOR SIGNAL

a. Inspect the VSC sensor signal.
47. INSPECT ACTUATOR WITH INTELLIGENT TESTER
48. INSPECT SRS WARNING LIGHT
49. PERFORM INITIALIZATION
a. Some systems need initialization after reconnecting the negative battery terminal.