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Brake Pedal: Installation

  1. INSTALL BRAKE PEDAL PAD 
  2. INSTALL CUSHION 
  3. INSTALL STOP LIGHT SWITCH ASSEMBLY 
    1. Temporarily install the stop light switch assembly with the lock nut.
    2. Fully tighten the stop light switch assembly with the lock nut after inspecting and adjusting brake pedal height (See ADJUSTMENT  ).
  4. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY 
    1. Install the brake pedal support assembly with the bolt.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 1: Locating Brake Pedal Support Assembly Bolt
      G04025314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the wire harness clamp.
    3. Connect the 2 connectors.
  5. INSTALL BRAKE BOOSTER GASKET 
  6. INSTALL BRAKE BOOSTER ASSEMBLY (See Step 4 in  INSTALLATION   ) 
  7. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (See Step 5 in  INSTALLATION   ) 
  8. INSTALL BRAKE PEDAL RETURN SPRING (See Step 6 in  INSTALLATION   ) 
    Fig 2: Connecting Connectors
    G04047766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY (See  INSTALLATION   ) 
  10. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission) (See Step 2 in  INSTALLATION   ) 
  11. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET (See Step 3 in  INSTALLATION  ) 
  12. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK (See Step 3 in  INSTALLATION   ) 
  13. CONNECT BATTERY NEGATIVE TERMINAL 
  14. ADD BRAKE FLUID (See  BLEEDING   ) 
  15. BLEED MASTER CYLINDER (See Step 2 in  BLEEDING   ) 
  16. BLEED BRAKE LINE (See Step 3 in  BLEEDING   ) 
  17. BLEED BRAKE ACTUATOR ASSEMBLY (See Step 4 in  BLEEDING   ) 
  18. BLEED AIR FROM CLUTCH LINE (for Manual Transmission) (See  BLEEDING  ) 
  19. INSPECT FLUID LEVEL IN RESERVOIR (See Step 5 in  BLEEDING   ) 
  20. INSPECT FOR BRAKE FLUID LEAKAGE 
  21. INSPECT AND ADJUST BRAKE PEDAL HEIGHT (See  ADJUSTMENT   ) 
  22. INSPECT PEDAL FREE PLAY (See Step 2 in  ADJUSTMENT   ) 
  23. INSPECT PEDAL RESERVE DISTANCE (See Step 3 in  ADJUSTMENT   ) 
  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 (See  INSTALLATION  ) 
  26. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See Step 24 in  INSTALLATION  ) 
  27. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See Step 25 in  INSTALLATION  ) 
  28. INSTALL INSTRUMENT SIDE PANEL LH (See Step 26 in  INSTALLATION  ) 
  29. INSTALL FRONT DOOR OPENING TRIM COVER LH (See Step 27 in  INSTALLATION  ) 
  30. INSTALL FRONT DOOR SCUFF PLATE LH (w/ Illumination) (See Step 90 in  INSTALLATION  ) 
  31. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See Step 88 in  INSTALLATION  ) 
  32. INSTALL FRONT WHEEL 
  33. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See Step 3 in  INSTALLATION  ) 
  34. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See Step 5 in  INSTALLATION  ) 
  35. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See Step 4 in  INSTALLATION  ) 
  36. INSTALL FRONT WIPER ARM HEAD CAP (See Step 6 in  INSTALLATION  ) 
  37. INSTALL ROOF DRIP SIDE FINISH MOLDING RH 
  38. INSTALL ROOF DRIP SIDE FINISH MOLDING LH 
  39. INSTALL FRONT UPPER FENDER PROTECTOR RH (See Step 9 in  INSTALLATION  ) 
  40. INSTALL FRONT UPPER FENDER PROTECTOR LH (See Step 10 in  INSTALLATION  ) 
  41. INSTALL ENGINE ROOM SIDE COVER RH (See Step 116 in  INSTALLATION  ) 
  42. INSTALL ENGINE ROOM SIDE COVER LH (See  INSTALLATION  ) 
  43. INSTALL COOL AIR INTAKE DUCT SEAL (See Step 118 in  INSTALLATION  ) 
  44. CONNECT BATTERY NEGATIVE TERMINAL 
  45. CHECK AND CLEAR DTC 
  46. INSPECT VSC SENSOR SIGNAL 
    1. Inspect the VSC sensor signal.
    SYSTEM REFERENCE

    System Proceed to
    w/o VDIM See DIAGNOSIS SYSTEM
  47. INSPECT ACTUATOR WITH INTELLIGENT TESTER 

    HINT:

    (See ON-VEHICLE INSPECTION )

  48. INSPECT SRS WARNING LIGHT 

    HINT:

    (See PROBLEM SYMPTOMS TABLE )

  49. PERFORM INITIALIZATION 
    1. Some systems need initialization after reconnecting the negative battery terminal (See INITIALIZATION ).
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