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Accelerator & Brake Pedal ASSY: Overhaul

  1. PRECAUTION (See  PRECAUTION  ) 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. REMOVE STEERING WHEEL COVER LOWER No. 2 
  4. REMOVE STEERING WHEEL COVER LOWER No. 2 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) 
  5. REMOVE POWER WINDOW LOCK SWITCH BULB (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) (See  STEERING COLUMN  ) 
  6. REMOVE STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY) (See  STEERING COLUMN  ) 
  7. INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  8. REMOVE HORN BUTTON ASSY (See  REPLACEMENT  ) 
  9. REMOVE STEERING WHEEL ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 

    SST 09950-50013 (09951 -05010, 09952-05010, 09953-05020, 09954-05021)

  10. REMOVE INSTRUMENT CLUSTER FINISH PANEL (See  REPLACEMENT  ) 
  11. REMOVE STEERING COLUMN COVER (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  12. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  13. REMOVE FRONT DOOR SCUFF PLATE LH (See  REPLACEMENT  ) 
  14. REMOVE COWL SIDE TRIM SUB-ASSY LH (See  REPLACEMENT  ) 
  15. REMOVE INSTRUMENT PANEL COIN BOX SUB-ASSY (See  REPLACEMENT  ) 
  16. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (See  REPLACEMENT  ) 
  17. REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH (See  REPLACEMENT  ) 
  18. REMOVE DUCT, FR VENTILATOR, LH (See  REPLACEMENT  ) 
  19. DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  20. REMOVE STEERING COLUMN ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  21. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSY 
    1. Remove the 3 nuts and junction block assy, then disconnect the connector. 
      Fig 1: Removing Instrument Panel Junction Block Assy
      G02593822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE BRAKE PEDAL RETURN SPRING 
    Fig 2: Removing Brake Pedal Return Spring
    G02593823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PUSH ROD PIN 
    1. Remove the clip and push rod pin.
      Fig 3: Removing Push Rod Pin
      G02593824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE ACCELERATOR & BRAKE PEDAL ASSY 
    1. Disconnect the stop lamp switch connector.
      Fig 4: Removing Accelerator And Brake Pedal Assy
      G02593825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the accel position sensor connector.
      Fig 5: Disconnecting Accel Position Sensor Connector
      G02593826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 4 nuts and accelerator & brake pedal assy.
      Fig 6: Removing Bolts, Nuts And Accelerator And Brake Pedal Assy
      G02593827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE STOP LAMP SWITCH ASSY 
    1. Loosen the nut and remove the stop lamp switch assy.
      Fig 7: Removing Stop Lamp Switch Assy
      G02593828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE BRAKE PEDAL PAD 
  27. REMOVE STOP LAMP SWITCH CUSHION 
    Fig 8: Removing Stop Lamp Switch Cushion
    G02593829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE ACCELERATOR PEDAL ASSY 
    1. Remove the bolt, nut and accelerator pedal assy.
    Fig 9: Removing Accelerator Pedal Assy
    G02593830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL ACCELERATOR PEDAL ASSY 
    1. Install the accelerator pedal assy with nut and bolt.

      Torque: 12 N.m (122 kgf.cm, 8.8 ft.lbf) 

    Fig 10: Installing Accelerator Pedal Assy
    G02593831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL STOP LAMP SWITCH CUSHION 
    Fig 11: Installing Stop Lamp Switch Cushion
    G02593832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL BRAKE PEDAL PAD 
  32. INSTALL STOP LAMP SWITCH ASSY 
    1. Install the stop lamp switch assy with a nut.

      Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) 

    Fig 12: Installing Stop Lamp Switch Assy
    G02593833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL ACCELERATOR & BRAKE PEDAL ASSY 
    1. Install the accelerator & brake pedal assy with the 4 nuts and 4 bolts.

      Torque: 

      Nut: 13 N.m (130 kgf.cm, 9 ft.lbf) 

      Bolt: 19.1 N.m (194 kgf.cm, 14 ft.lbf) 

      Fig 13: Installing Accelerator And Brake Pedal Assy
      G02593834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the accel position sensor connector.
      Fig 14: Connecting Accel Position Sensor Connector
      G02593835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the stop lamp switch connector.
      Fig 15: Connecting Stop Lamp Switch Connector
      G02593836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL PUSH ROD PIN 
    1. Install the push rod pin and clip.

      HINT:

      Apply the lithium soap base glycol grease to the parts indicates by arrows (See COMPONENTS  ).

      Fig 16: Installing Push Rod Pin
      G02593837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL BRAKE PEDAL RETURN SPRING 
    Fig 17: Installing Brake Pedal Return Spring
    G02593838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY 
    1. Install the junction block assy with the 3 nuts, then connect the each connector.
      Fig 18: Installing Instrument Panel Junction Block Assy
      G02593839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL STEERING COLUMN ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  38. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  39. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  40. CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  41. CHECK KEY INTERLOCK OPERATION 
  42. INSTALL STEERING COLUMN COVER (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  43. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See  REPLACEMENT  ) 
  44. INSTALL DUCT, FR VENTILATOR, LH (See  REPLACEMENT  ) 
  45. INSTALL INSTRUMENT PNL INSERT SUB-ASSY LWR LH (See  REPLACEMENT  ) 
  46. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (See  REPLACEMENT  ) 
  47. INSTALL INSTRUMENT PANEL COIN BOX SUB-ASSY (See  REPLACEMENT  ) 
  48. INSTALL COWL SIDE TRIM SUB-ASSY LH (See  REPLACEMENT  ) 
  49. INSTALL FRONT DOOR SCUFF PLATE LH (See  REPLACEMENT  ) 
  50. CENTER SPIRAL CABLE (See  SPIRAL CABLE SUB-ASSY  ) 
  51. INSTALL STEERING WHEEL ASSY (See  STEERING COLUMN ASSY (TMC MADE)  ) 
  52. INSPECT HORN BUTTON ASSY (See  REPLACEMENT  ) 
  53. INSTALL HORN BUTTON ASSY (See  REPLACEMENT  ) 
  54. INSTALL STEERING WHEEL COVER LOWER No. 2 
  55. INSTALL STEERING WHEEL COVER LOWER NO.3 (W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) 
  56. INSTALL POWER WINDOW LOCK SWITCH BULB (W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) 
  57. INSTALL STEERING WHEEL COVER LOWER NO.3 (3 SPOKE STEERING WHEEL ASSY) 
  58. INSPECT STEERING WHEEL CENTER POINT 
  59. INSPECT SRS WARNING LIGHT (See  DTC CHECK/CLEAR  ) 
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