BRAKE PEDAL REMOVAL/INSTALLATION [L.H.D.]

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Caution
•  The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch is inserted into the installation hole on the brake pedal and rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake pedal is properly installed and fully released before installing the brake switch to the pedal.
•  Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again. Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or performing any procedure that changes the pedal stroke.
•  Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. In addition, if there is any brake fluid on the wiring harness, the wire insulation may corrode causing a malfunction such as a short circuit. If brake fluid gets on a painted surface or wiring harness, wash and flush it off completely with water immediately.

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT i-stop)].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

2.  Remove the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Disconnect the brake pipes from the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [L.H.D.].)

4.  For MTX vehicles, disconnect the clutch reserve hose from the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION [L.H.D.].)

5.  Remove the side wall (driver side). (See SIDE WALL REMOVAL/INSTALLATION.)

6.  Remove the front heat duct (LH). (See FRONT HEAT DUCT REMOVAL/INSTALLATION.)

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See BRAKE FLUID AIR BLEEDING.)

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1
Brake switch connector and wiring harness
2
Brake switch
(See Brake Switch Installation Note.)
3
Spring pin
4
Clevis pin
5
Nut
6
Nut
7
Brake pedal
(See Brake Pedal Removal Note.)
8
Pedal pad


Brake Pedal Removal Note

1.  Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.

2.  Remove the brake pedal.


Brake Switch Installation Note

1.  Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)

2.  With the brake pedal fully released, insert a new brake switch into the installation hole on the brake pedal.

3.  Secure the brake switch by turning it counterclockwise 45°.

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