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Home >> Chevrolet >> 2002 >> Prizm LSi, Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brakes >> Repair Instructions >> Brake Pedal Replacement >> Installation Procedure

Installation Procedure

  1. Install the cover to the brake pedal (3).
  2. Lubricate the brake pedal bushings using Lubriplate lubricant, GM P/N 12346293 (or equivalent). Use a lubricant that meets the requirements of NLGI 2 Category LB or GC-LB.
  3. Install the brake pedal bushings to the brake pedal.
    NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  4. Install the brake pedal to the bracket. Secure with the brake pedal shaft bolt and nut.

    Tighten 

    Tighten the bolt and the nut to 20 N.m (14.75 in lbs).

  5. Install the brake pedal and bracket assembly to the vehicle. Secure with the brake pedal bracket mounting nuts.

    Tighten 

    Tighten the nuts to 10 N.m (89 in lbs).

  6. Install the brake pedal bracket front bolt.

    Tighten 

    Tighten the bolt to 20 N.m (14.75 ft lbs).

  7. Connect the brake light switch electrical connector.
  8. Install the following components:
    • The wave washer
    • The clevis pin
    • The R-clip
    • The brake pedal return spring
  9. Install the LH ventilation duct.
    Fig 1: Installing Brake Pedal Components
    G01711080Courtesy of GENERAL MOTORS CORP.
  10. Install the knee bolster. Secure with 2 bolts.

    Tighten 

    Tighten the bolts to 10 N.m (89 in lbs).

  11. Install the knee bolster trim panel (1). Secure with 2 bolts (3).

    Tighten 

    Tighten the bolts to 10 N.m (89 in lbs).

  12. Connect the hood release lever. Secure with 2 screws.
    Fig 2: Installing Knee Bolster Trim Panel
    G01711081Courtesy of GENERAL MOTORS CORP.
  13. Install the LH kick panel (2). Secure with 1 nut (1).

    Tighten 

    Tighten the nut to 5.4 N.m (48 in lbs).

  14. Connect the negative battery cable.
  15. Inspect the Brake Pedal Travel. Refer to Brake Pedal Travel Measurement and Inspection .
    Fig 3: Installing LH Kick Panel
    G01711082Courtesy of GENERAL MOTORS CORP.