Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 2004-2007 Approved SRM 21 32 209gw x040001
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32-9
BRAKE - BRAKE PEDAL SUPPORT ASSY
320UY-02
REPLACEMENT
1. SEPARATE BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT DOOR SCUFF PLATE LH
3. REMOVE COWL SIDE TRIM BOARD LH
4. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER LH
(a) Remove the 2 bolts and instrument panel finish panel sub-assy lower LH.
5. REMOVE INSTRUMENT PANEL SAFETY PAD INSERT SUB-ASSY NO.1
(a) Remove the 4 bolts and instrument panel safety pad insert sub-assy No.1.
6. LOOSEN BRAKE PEDAL SHAFT
(a) Loosen the 2 brake pedal shafts.
F45360
7. REMOVE BRAKE PEDAL SUPPORT ASSY
(a) Remove the 4 nuts and brake pedal support sub-assy.
(b) Using needle-nose pliers, remove the tension spring.
(c) Remove the clip and clevis pin from the brake pedal lever.
G24262
(d) Remove the 2 bolts from the brake pedal bracket No.3.
(e) Remove the stop lamp switch harness clamp from the
brake pedal support sub-assy.
(f) Disconnect the stop lamp switch connctor.
G24263
8. REMOVE STOP LAMP SWITCH ASSY
(a) Turn the stop lamp switch assy counterclockwise and remove the stop lamp switch assy.
(b) Remove the stop lamp switch mounting adjuster from the brake pedal support sub-assy.
9. REMOVE STOP LAMP SWITCH CUSHION
(a) Remove the stop lamp switch cushion from the brake pedal sub-assy.
10. REMOVE BRAKE PEDAL
(a) Remove the 2 brake pedal shafts, 2 nuts and brake pedal from the brake pedal support sub-assy.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2757
32-10
BRAKE - BRAKE PEDAL SUPPORT ASSY
11. REMOVE BRAKE PEDAL BUSH
(a) Remove the 4 brake pedal bushes from the brake pedal.
12. REMOVE BRAKE PEDAL SHAFT COLLAR
(a) Remove the 2 brake pedal shaft collars from the brake pedal.
13. REMOVE PUSH ROD PIN
(a) Using a screwdriner, remove the 2 E-rings, 2 push rod
pins and 2 plates from the brake pedal.
(b) Remove the 2 push rod bushes.
F45359
14. REMOVE BRAKE PEDAL PAD
(a) Remove the brake pedal pad to the brake pedal sub-assy.
15. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal sub-assy.
16. INSTALL PUSH ROD PIN
(a) Apply lithium soap base glycol grease to inside surface of 2 new push rod bushes.
(b) Install the 2 new push rod bushes.
(c) Install the 2 push rod pins with the 2 plate to the brake pedal.
(d) Using needle-nose pliers, install the 2 new E-rings to the 2 push rod pins.
NOTICE:
Install the E-ring securely to the grooves of the push rod pin.
17. INSTALL BRAKE PEDAL BUSH
(a) Apply lithium soap base glycol grease to inside surface of 4 new brake pedal bushes.
(b) Install the 4 brake pedal bushs to the brake pedal.
18. INSTALL BRAKE PEDAL SHAFT COLLAR
(a) Apply the lithium soap base glycol grease to inside surface of 2 brake pedal shaft collars.
(b) Install the 2 brake pedal shaft collars to the brake pedal.
19. INSTALL BRAKE PEDAL
(a) Install the 2 brake pedal shafts, 2 nuts, brake pedal and brake pedal bracket No.3 to the brake pedal
support sub-assy.
20. INSTALL STOP LAMP SWITCH CUSHION
(a) Install the stop lamp switch cushion to the brake pedal sub-assy.
21. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch mounting adjuster to the brake pedal support sub-assy.
(b) Install the stop lamp switch assy until the body hits the cushion.
(c) Make a quarter turn clockwise to install the stop lamp switch assy.
NOTICE:
The turning torque for installing the stop lamp switch assy.
Torque: 1.5 Nm (15 kgfcm, 13 in.lbf) or less
HINT:
Due to the inverse screw structure, if the stop lamp switch assy is turned clockwise, the stop lamp switch
assy moves in the direction to be pulld out.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2758
32-1 1
BRAKE - BRAKE PEDAL SUPPORT ASSY
22. INSTALL BRAKE PEDAL SUPPORT ASSY
(a) Install the brake pedal support sub-assy with the 4 nuts.
Torque: 16 Nm (160 kgfcm, 12 ft.lbf)
(b) Install the clip and clevis pin to the brake pedal lever.
(c) Using needle-nose pliers, install the tension spring.
G24262
(d) Install the 2 bolts to the brake pedal bracket No.3.
Torque: 19 Nm (194 kgfcm, 14 ft.lbf)
(e) Install the stop lamp switch harness clamp to the brake
pedal support sub-assy.
(f) Connect the stop lamp switch connctor.
G24263
23. FULLY TIGHTEN BRAKE PEDAL SHAFT
(a) fully tighten the 2 brake pedal shafts.
Torque: 34 Nm (350 kgfcm, 25 ft.lbf)
F45360
24. INSTALL INSTRUMENT PANEL SAFETY PAD INSERT SUB-ASSY NO.1
(a) Install the instrument panel safety pad insert sub-assy No.1 with the 4 bolts.
25. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER LH
(a) Install the instrument panel finish panel sub-assy lower LH with the 2 bolts.
26. INSTALL COWL SIDE TRIM BOARD LH
27. INSTALL FRONT DOOR SCUFF PLATE LH
28. INSPECT BRAKE PEDAL HEIGHT (See page 32-6 )
29. CHECK PEDAL FREE PLAY (See page 32-6 )
30. CHECK PEDAL RESERVE DISTANCE (See page 32-6 )
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2759
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