Orlando

Brake, Accelerator, and Clutch Pedal Replacement - Left Hand Drive

1. Remove the battery. Refer to Battery Replacement : Petrol → Diesel .
2. Remove the battery tray. Refer to Battery Tray Replacement .
3. Remove dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .




Note: Do NOT disconnect engine coolant hoses.

4. Remove the radiator surge tank clip (2).
5. Remove the radiator surge tank (1).

Position the radiator surge tank (1) aside.




6. Remove the BPMV bracket bolts (1).



7. Remove the brake booster bolts (1).




Note: 

•	Do NOT open hydraulic brake system.

•	Second mechanic required.

8. Pull the brake booster and the BPMV assembly forward in order to get access to the brake pedal bracket nuts (1).
9. Remove the brake pedal bracket nuts (1).
10. Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement .
11. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement .
12. Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement .
13. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .
14. Remove the steering column. Refer to Steering Column Replacement .



15. Disconnect the brake pedal pushrod (1) from the brake pedal with brake pedal applied a bit.



16. Replace click fit connector (1) between booster pushrod and brake pedal with new part.



17. Remove the clutch master cylinder nuts (2) from the pedal bracket, if equipped.
18. Disconnect clutch master cylinder push rod (1) from the clutch pedal, if equipped.



19. Remove the brake pedal bracket bolt (1) from the tie bar.
20. Separate wiring harness from pedal bracket.
21. Disconnect electrical connectors.



22. Carefully bend the fuse box bracket (1) to the side to allow space for pedal assembly removal.
23. Remove brake and accelerator and clutch pedal assembly from vehicle.
24. Transfer component parts as needed.

1. Install the brake and accelerator and clutch pedal assembly to the vehicle.
2. Carefully bend the fuse box bracket (1) back in position
3. Install wiring harness to brake pedal bracket.
4. Connect electrical connectors.

Caution: Refer to Fastener Caution in the Preface section.

5. Install brake pedal bracket bolts and tighten to 20 N·m (15 lb ft).
6. Connect clutch master cylinder push rod (1) to the clutch pedal, if equipped.



7. Install the clutch master cylinder nuts (2) to the pedal bracket, if equipped and tighten to 18 N·m (13 lb ft).



8. Connect the brake pedal pushrod (1) to the brake pedal.
9. Install the steering column. Refer to Steering Column Replacement .
10. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .
11. Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement .
12. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement .
13. Install the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement .




Note: 

•	Do NOT open hydraulic brake system.

•	Second mechanic required.

14. Pull the brake booster and the BPMV assembly forward in order to gain access to the brake pedal bracket nuts (1).
15. Install the pedal bracket nuts (1) and tighten to 20 N·m (15 lb ft).



16. Install the brake servo unit bolts (1) and tighten to 19 N·m (14 lb ft).



17. Install the BPMV bracket bolts (1) and tighten to 20 N·m (15 lb ft).




Note: Do NOT disconnect engine coolant hoses.

18. Install the radiator surge tank (1).
19. Install the radiator surge tank clip (2).
20. Install dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .
21. Install the battery tray. Refer to Battery Tray Replacement .
22. Install the battery. Refer to Battery Replacement : Petrol → Diesel .
23. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .