Brake Pedal Assy: Service and Repair

Brake Pedal Assembly Replacement

Removal Procedure

Danger: Do not use a service jack to lift this vehicle. Lifting the vehicle with a jack could cause the vehicle to slip off the jack and roll; this could cause injury or death.


1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.




2. Remove the brake pressure modulator valve (BPMV) bracket bolt (1).
3. Lower the vehicle.
4. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement Air Cleaner Resonator Outlet Duct Replacement.
5. Remove the front suspension strut housing brace. Refer to Front Suspension Strut Housing Brace Replacement Service and Repair.
6. Remove the bolt and position aside the accessory wiring junction block. Refer to Accessory Wiring Junction Block Replacement Accessory Wiring Junction Block Replacement.





Note: Do not reuse the master cylinder nuts.

7. Remove and discard the 2 master cylinder nuts (1).




8. Remove the BPMV bracket nut (1).




9. Remove the BPMV bracket bolt (1).

Note: Do not bend the brake pipes.

10. Carefully remove and position aside the master cylinder and the BPMV and bracket assembly. Support the components with heavy mechanics wire or equivalent.




11. Remove the brake pedal assembly nuts (1).
12. Remove the front floor console. Refer to Front Floor Console Replacement Front Floor Console Replacement.
13. Remove the left side floor front air outlet duct. Refer to Floor Front Air Outlet Duct Replacement - Left Side Floor Front Air Outlet Duct Replacement - Left Side.
14. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.
15. Remove the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement Service and Repair.
16. Disconnect the brake pedal position sensor electrical connector.
17. Disconnect the electronic brake pedal travel sensor electrical connector.




18. Remove the left upper brake pedal assembly bolts (1).




19. Remove the right upper brake pedal assembly bolts (1).
20. Without removing the instrument panel tie bar assembly, remove the fasteners retaining the tie bar assembly to the vehicle. Refer to Instrument Panel Tie Bar Replacement Instrument Panel Tie Bar Replacement.
21. With the aid of an assistant, pull the instrument panel and tie bar assembly rearward and upward approximately 25 mm (1 in) and remove the brake pedal assembly.

Installation Procedure

1. With the aid of an assistant, pull the instrument panel and tie bar assembly rearward and upward approximately 25 mm (1 in) and install the brake pedal assembly.
2. Install the fasteners retaining the tie bar assembly to the vehicle. Refer to Instrument Panel Tie Bar Replacement Instrument Panel Tie Bar Replacement.





Caution: Refer to Fastener Caution Fastener Caution.

3. Install the right upper brake pedal assembly bolts (1) and tighten to 12 Nm (106 lb in).




4. Install the left upper brake pedal assembly bolts (1) and tighten to 12 Nm (106 lb in).
5. Connect the brake pedal position sensor electrical connector.
6. Connect the electronic brake pedal travel sensor electrical connector.
7. Install the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement Service and Repair.
8. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.
9. Install the left side floor front air outlet duct. Refer to Floor Front Air Outlet Duct Replacement - Left Side Floor Front Air Outlet Duct Replacement - Left Side.
10. Install the front floor console. Refer to Front Floor Console Replacement Front Floor Console Replacement.




11. Install the brake pedal assembly nuts (1) and tighten to 23 Nm (17 lb ft).
12. Apply silicone brake lubricant to the brake master cylinder pushrod tip.

Note: Do not bend the brake pipes.

13. Carefully reposition the master cylinder and the BPMV and bracket assembly to the vehicle.




14. Install the BPMV bracket bolt (1) and tighten to 22 Nm (16 lb ft).




15. Install the BPMV bracket nut (1) and tighten to 22 Nm (16 lb ft).





Note: Install new master cylinder nuts.

16. Install 2 new master cylinder nuts (1) and tighten to 22 Nm (16 lb ft).
17. Reposition the accessory wiring junction block and install the bolt. Refer to Accessory Wiring Junction Block Replacement Accessory Wiring Junction Block Replacement.
18. Install the front suspension strut housing brace. Refer to Front Suspension Strut Housing Brace Replacement Service and Repair.
19. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement Air Cleaner Resonator Outlet Duct Replacement.
20. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.




21. Install the BPMV bracket bolt (1) and tighten to 22 Nm (16 lb ft).
22. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration.