Installation

BRAKE PEDAL:

INSTALLATION

1. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad onto the brake pedal.
2. INSTALL BRAKE PEDAL LEVER
(a) Apply lithium soap base glycol grease to the 2 brake pedal link pins, 2 pedal shaft collars and 2 brake pedal links.
(b) Install the brake pedal lever with the 2 brake pedal link pins, 2 brake pedal shaft collars and 2 brake pedal links onto the brake pedal.
(c) Install 2 new E-rings onto each brake pedal link pin.
3. INSTALL BRAKE PEDAL
(a) Apply lithium soap base glycol grease to the 2 collars and 4 brake pedal bushes.
(b) Install the 2 collars and 4 brake pedal bushes onto the brake pedal and brake pedal lever.





(c) Install the brake pedal with the bolt and nut onto the brake pedal support.
Torque: 34 Nm (350 kgf-cm, 25 ft-lbf)
4. INSTALL STOP LIGHT SWITCH ASSEMBLY





(a) Insert the stop light switch until the body comes into contact with the cushion.

NOTE: When inserting the stop light switch, support the pedal from behind so that the pedal is not pushed in.





(b) Make a quarter turn clockwise to install the stop light switch.

NOTE: The turning torque for installing the stop light switch:

Torque: 1.5 Nm (15 kgf-cm, 13 in-lbf)

HINT: Due to the inverse screw structure, turning the stop light switch clockwise will cause it to become loose and eventually detach from the adjuster.

(c) Check the protrusion of the rod.
Protrusion of the rod:
1.5 to 2.5 mm (0.059 to 0.098 in.)
5. INSTALL BRAKE PEDAL RETURN SPRING
(a) Apply lithium soap base glycol grease to the inner surface of the hole on the brake pedal support and brake pedal.
(b) Install the return spring onto the brake pedal support and brake pedal.





6. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
(a) Install the 4 nuts and brake pedal support.
Torque: 14 Nm (145 kgf-cm, 10 ft-lbf)
(b) Connect the stop light switch connector to the stop lamp switch.
7. INSTALL BRAKE PEDAL SUPPORT REINFORCEMENT
(a) Install the reinforcement onto the brake pedal support.





(b) Provisionally tighten the bolt and nut to the brake pedal support, reinforcement and brake pedal lever.





(c) Install the bolt onto the reinforcement.
Torque: 34 Nm (350 kgf-cm, 25 ft-lbf)
(d) Tighten the bolt and nut.
Torque: 34 Nm (350 kgf-cm, 25 ft-lbf)
8. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
(a) Apply lithium soap base glycol grease to the inner surface of the hole on the brake pedal lever.
(b) Install the push rod clevis onto the brake pedal lever with the push rod pin and clip.
9. INSPECT BRAKE PEDAL HEIGHT (Testing and Inspection)

10. INSPECT PEDAL FREE PLAY (Testing and Inspection)

11. INSPECT PEDAL RESERVE DISTANCE (Testing and Inspection)

12. INSTALL DRIVER SIDE JUNCTION BLOCK
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
13. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO. 1 (Installation)

14. INSTALL INSTRUMENT PANEL UNDER TRAY (for Automatic Transmission) (Installation)

15. INSTALL INSTRUMENT PANEL HOLE COVER (for Manual Transmission) (Installation)

16. INSTALL COWL SIDE TRIM BOARD (for Regular Cab) (Installation)

17. INSTALL COWL SIDE TRIM BOARD (for Access Cab) (Installation)

18. INSTALL COWL SIDE TRIM BOARD (for Double Cab) ()

19. INSTALL FRONT DOOR SCUFF PLATE (for Regular Cab) (Installation)

20. INSTALL FRONT DOOR SCUFF PLATE (for Access Cab) (Installation)

21. INSTALL FRONT DOOR SCUFF PLATE (for Double Cab) ()

22. INSTALL FRONT FLOOR FOOTREST (Installation)

23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 in-lbf)