Installing Brake Pedal

Information 

The pedal shaft must not be greased during installation! 

The cover on the pedal shaft is coded. This means that the pedal shaft can only be fitted correctly in one specific position.

When sliding in the brake pedal shaft -1-  , make sure that the cut-out -2-  on the brake pedal shaft fits into the guide -3-  on the holder -4-  . This is the only way to ensure that the pedal shaft is installed at the correct position and will not turn.

Fig 1: Positioning Brake Pedal Shaft

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1. Install brake pedal.
   Fig 2: Pressing Brake Pedal Shaft

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   1. 1.1. Fit the brake pedal -2-  into the pedal system -arrow A-  .
   2. 1.2. Press the brake pedal shaft -1-  fully into the brake pedal -2-  (-arrow B-  ).

      Information 

      The pedal shaft must not be greased during installation! 

      The cover on the pedal shaft is coded. This means that the pedal shaft can only be fitted correctly in one specific position.

      When sliding in the brake pedal shaft -1-  , make sure that the cut-out -2-  on the brake pedal shaft fits into the guide -3-  on the holder -4-  .

      This is the only way to ensure that the pedal shaft is installed at the correct position and will not turn.

      Fig 3: Positioning Brake Pedal Shaft

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   3. 1.3. Slide the lock -1-  at the left onto the brake pedal shaft -2-  (-arrow-  ).
      Fig 4: Fitting Brake Pedal Lock

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2. Secure the pedals.

   Observe the relevant tightening torques. WM 4X00IN TIGHTENING TORQUES FOR BRAKE MECHANISM/BRAKE HYDRAULIC SYSTEM

   1. 2.1. Position the pedals at the firewall and align them.
      Fig 5: Locating Pedals Screws

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   2. 2.2. Tighten inner fastening nuts -arrows-  .
   3. 2.3. Screw in fastening screws above the brake booster.
      Fig 6: Locating Pedals Fastening Nuts

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   4. 2.4. Screw in fastening screws on the brake booster.
      Fig 7: Locating Brake Booster Fastening Screws

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3. Fit push rod for brake booster.
   1. 3.1. Position the brake pedal -1-  on the push rod for the brake booster -2-  .
      Fig 8: Fitting Push Rod

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   2. 3.2. Press the brake pedal -1-  through fully -arrow A-  until the push rod -2-  clicks into place in the holder on the brake pedal -3-  (-arrow B-  ).
   3. 3.3. Check that the push rod -2-  is fully engaged in the holder -1-  .
      Fig 9: Fitting Push Rod

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4. Engage clutch master cylinder. (Only for manual transmission) 
   1. 4.1. Position the clutch master cylinder -arrow A-  and lock it by turning it clockwise -arrow B-  .
      Fig 10: Installing Clutch Master Cylinder

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   2. 4.2. Press in retaining clip for push rod -1-  in the clutch pedal -2-  (-arrow-  ) until it clicks into place.
      Fig 11: Engaging Push Rod

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5. Release clutch power spring assembly. (Only for manual transmission) 
   1. 5.1. Press the clutch pedal -1-  slightly -arrow A-  until the cotter pin -3-  can be pulled out of the clutch power spring axle -2-  (-arrow B-  ).
      Fig 12: Releasing Clutch Power Spring Assembly

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   2. 5.2. Press rubber sleeve into the plenum panel -arrow-  .
      Fig 13: Pressing Rubber Sleeve Into Plenum Panel

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