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Home >> Saturn >> 2006 >> Relay 3.5 L, FWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brakes >> Repair Instructions >> Brake Pedal Assembly Replacement >> Installation Procedure

Installation Procedure

  1. Install the brake pedal position sensor to the brake pedal assembly. Refer to Brake Pedal Position Sensor Replacement .
  2. Fig 1: Identifying Brake Pedal Assembly Components
    GM180294Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  3. Position the brake pedal brace (4) to the brake pedal assembly and install the brace mounting nuts (1).

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

  4. Install the brake pedal assembly (3) with the brace to the vehicle.
  5. Push the master cylinder and brake booster assembly back into position.
  6. Install the brake pedal brace (4) upper mounting bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  7. Install the brake pedal assembly mounting nuts (2).

    Tighten:  Tighten the nuts (2) to 25 N.m (18 lb ft).

  8. Install the digital radio receiver and bracket if equipped. Refer to Digital Radio Receiver Replacement .
  9. Fig 2: Locating Brake Pedal Assembly Components
    GM180291Courtesy of GENERAL MOTORS CORP.
  10. Install the brake booster mounting nuts (3).

    Tighten:  Tighten the nuts (3) to 25 N.m (18 lb ft).

  11. Install the booster push rod (2) to the brake pedal (1).
  12. Install washer and retain clip.
  13. Install the accelerator pedal. Refer to Accelerator Pedal Position Sensor Replacement .
  14. Enable the SIR system. Refer to SIR Disabling and Enabling .
  15. Connect the electrical connector to the stop lamp switch.
  16. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .
  17. Install the knee bolster. Refer to Knee Bolster, Insulator, Molding Replacement - Instrument Panel .
  18. Install the left side insulator panel. Refer to Upper Trim Pad, Outer Trim Cover, Fuse Block Access Cover Replacement - Instrument Panel .