Brake Pedal (For Sedan) Installation

Install the brake pedal pad onto the brake pedal.

Apply lithium soap base glycol grease to the 2 bushes.

Install the 2 bushes onto the brake pedal.

Install the brake pedal onto the pedal support with the brake pedal shaft and nut.

Torque:

37 N*m{375 kgf*cm, 27 ft.*lbf}

Install the pedal support with the bolt and 4 nuts.

Torque:

Bolt:

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

Nut:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

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

Install the push rod clevis with the push rod pin and clip.

Install the brake pedal return spring.

Install a new stop light switch mounting adjuster onto the pedal support.

Insert the stop light switch into the adjuster until it just touches the brake pedal.

NOTICE:

Do not depress the brake pedal.

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

NOTICE:

Do not depress the brake pedal.

HINT:

The turning torque for installing the stop light switch:

Torque:

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

Check the stop light switch clearance.

Stop light switch clearance:

0.5 to 2.6 mm (0.020 to 0.102 in.)

Connect the wire harness clamp onto the pedal support.

Connect the connector to the stop light switch.

Inspect the brake pedal height.

Pedal height from floor:

w/ ABS	w/o ABS
113.1 to 123.1 mm (4.45 to 4.85 in.)	107.8 to 117.8 mm (4.244 to 4.638 in.)

Adjust the brake pedal height.

1. Disconnect the connector from the stop light switch.
   

2. Turn the stop light switch counterclockwise, and remove the stop light switch.
   

3. Loosen the push rod lock nut.
   

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

   Pedal height from floor:

   w/ ABS	w/o ABS
   113.1 to 123.1 mm (4.45 to 4.85 in.)	107.8 to 117.8 mm (4.244 to 4.638 in.)

5. Tighten the push rod lock nut.
   

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}





6. Insert the stop light switch into the adjuster until it just touches the brake pedal.
   

   NOTICE:

   Do not depress the brake pedal.





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

   NOTICE:

   Do not depress the brake pedal.

   HINT:

   The turning torque for installing the stop light switch:

   Torque:

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

8. Check the stop light switch clearance.
   

   Stop light switch clearance:

   0.5 to 2.6 mm (0.020 to 0.102 in.)
   

9. Connect the connector to the stop light switch.
   

Inspect the brake pedal free play.

1. Stop the engine and depress the brake pedal several times until there is no vacuum left in the booster.
   

2. Push in the pedal until the beginning of the resistance is felt. Measure the distance as shown.
   

   Pedal free play:

   1.0 to 6.0 mm (0.039 to 0.236 in.)
   

   If incorrect, troubleshoot the brake system.
   

Inspect the brake pedal reserve distance.

1. Release the parking brake lever. With the engine running, depress the pedal and measure the pedal reserve distance as shown.
   

   Pedal reserve distance from floor at 294 N (30 kgf, 66.1 lbf):

   for ABS with VSC	for ABS without VSC	w/o ABS
   More than 76 mm (2.99 in.)	More than 73 mm (2.87 in.)	More than 70 mm (2.75 in.)

   HINT:

   Sound and resistance from the brake booster when the brake pedal is depressed without a vacuum does not indicate a problem.

   If incorrect, troubleshoot the brake system.
   

Connect all the connectors and clamp the wire harnesses onto the steering column assembly bracket.

Align the matchmarks on steering intermediate shaft assembly No. 2 and the steering sliding yoke and provisionally install them with bolt C.

Torque:

35 N*m{360 kgf*cm, 26 ft.*lbf}

Align the matchmarks on the steering sliding yoke and steering gear assembly and install them with bolt B.

Torque:

35 N*m{360 kgf*cm, 26 ft.*lbf}

Tighten bolt A.

Torque:

35 N*m{360 kgf*cm, 26 ft.*lbf}

Install the column hole cover plate with the 2 clips.

Install the floor carpet.

Engage the 2 claws and 2 clips and install the instrument panel finish panel lower center.