BRAKE PEDAL REMOVAL/INSTALLATION [L.H.D.]

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Caution
•  The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch is inserted into the installation hole on the brake pedal and rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake pedal is properly installed and fully released before installing the brake switch to the pedal.
•  Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again. Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or performing any procedure that changes the pedal stroke.

1.  Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.3, SKYACTIV-G 1.5].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

•  Fresh-air duct
•  Air hose
•  Air cleaner cover
•  Air cleaner element
•  Resonance chamber (SKYACTIV-G 1.5)
•  Air cleaner case

2.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 1.3, SKYACTIV-G 1.5].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

3.  For the SKYACTIV-D 1.5 (i-ELOOP) vehicle, perform the following procedure.

(1)  Remove the DC-DC converter (i-ELOOP) installation bolt. (See DC-DC CONVERTER (i-ELOOP) REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-D 1.5)].)
(2)  Disconnect the DC-DC converter (i-ELOOP) connector. (See DC-DC CONVERTER (i-ELOOP) REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-D 1.5)].)
(3)  Set the DC-DC converter (i-ELOOP) out of the way.

4.  Remove the insulator.

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5.  Detach the brake pipes from the clip.

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6.  Remove in the order indicated in the table.

7.  Install in the reverse order of removal.

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1
Brake switch connector and wiring harness
2
Brake switch
(See Brake Switch Installation Note.)
3
Snap pin
(See Snap Pin Installation Note.)
4
Clevis pin
5
Nut
(See Nut Installation Note.)
6
Brake pedal
(See Brake Pedal Removal Note.)
7
Pedal pad


Brake Pedal Removal Note

1.  Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.

2.  Remove the brake pedal.


Nut Installation Note

1.  Temporarily tighten the nuts A and B.

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2.  Tighten the nuts A to the specified torque.

3.  Tighten the nuts B to the specified torque.


Snap Pin Installation Note

1.  Install the snap pin as shown in the figure.

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Brake Switch Installation Note

1.  Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)

2.  With the brake pedal fully released, insert a new brake switch into the installation hole on the brake pedal.

3.  Secure the brake switch by turning it counterclockwise 45°.

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