Volt

Brake Pedal Assembly Replacement

1. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
2. Remove the front suspension strut housing brace. Refer to Front Suspension Strut Housing Brace Replacement .
3. Remove the bolt and position aside the engine wiring junction block.




Note: Do not reuse the master cylinder nuts.

4. Remove and discard the 2 master cylinder nuts (1).



5. Remove the brake pressure modulator valve (BPMV) bracket nut (1).



6. Remove the BPMV bracket bolt (1).



7. Remove the BPMV bracket bolt (1).

Note: Do not bend the brake pipes.

8. Carefully remove and position aside the master cylinder and the BPMV and bracket assembly. Support the components with heavy mechanics wire or equivalent.



9. Remove the brake pedal assembly nuts (1).
10. Remove the front floor console. Refer to Front Floor Console Replacement .
11. Remove the left side floor front air outlet duct. Refer to Floor Front Air Outlet Duct Replacement - Left Side .
12. Remove the steering column. Refer to Steering Column Replacement .
13. Remove the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement .
14. Disconnect the brake pedal position sensor electrical connector.
15. Disconnect the electronic brake pedal travel sensor electrical connector.



16. Remove the left upper brake pedal assembly bolts (1).



17. Remove the right upper brake pedal assembly bolts (1).
18. Without removing the instrument panel tie bar assembly, remove the fasteners retaining the tie bar assembly to the vehicle. Refer to Instrument Panel Tie Bar Replacement .
19. With the aid of an assistant, pull the instrument panel and tie bar assembly rearward and upward approximately 25 mm (1 in) and remove the brake pedal assembly.

1. With the aid of an assistant, pull the instrument panel and tie bar assembly rearward and upward approximately 25 mm (1 in) and install the brake pedal assembly.
2. Install the fasteners retaining the tie bar assembly to the vehicle. Refer to Instrument Panel Tie Bar Replacement .

Caution: Refer to Fastener Caution in the Preface section.




3. Install the right upper brake pedal assembly bolts (1) and tighten to 12 N·m (106 lb in).



4. Install the left upper brake pedal assembly bolts (1) and tighten to 12 N·m (106 lb in).
5. Connect the brake pedal position sensor electrical connector.
6. Connect the electronic brake pedal travel sensor electrical connector.
7. Install the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement .
8. Install the steering column. Refer to Steering Column Replacement .
9. Install the left side floor front air outlet duct. Refer to Floor Front Air Outlet Duct Replacement - Left Side .
10. Install the front floor console. Refer to Front Floor Console Replacement .



11. Install the brake pedal assembly nuts (1) and tighten to 23 N·m (17 lb ft).
12. Apply silicone brake lubricant to the brake master cylinder pushrod tip.

Note: Do not bend the brake pipes.

13. Carefully reposition the master cylinder and the BPMV and bracket assembly to the vehicle.



14. Install the BPMV bracket bolt (1) and tighten to 22 N·m (16 lb ft).



15. Install the BPMV bracket bolt (1) and tighten to 22 N·m (16 lb ft).



16. Install the BPMV bracket nut (1) and tighten to 22 N·m (16 lb ft).




Note: Install new master cylinder nuts.

17. Install 2 new master cylinder nuts (1) and tighten to 22 N·m (16 lb ft).
18. Install the engine wiring junction block and bolt.
19. Install the front suspension strut housing brace. Refer to Front Suspension Strut Housing Brace Replacement .
20. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
21. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .