Astra J
Brake, Accelerator, and Clutch Pedal Replacement (Right Hand Drive)Removal Procedure
|
| 1. | Remove the air cleaner assembly. Refer to: |
| • | 1.3 L diesel engine. Refer to Air Cleaner Replacement . |
| • | 1.4 L engine. Refer to Air Cleaner Assembly Replacement . |
| • | 1.6 L engine. Refer to Air Cleaner Assembly Replacement . |
| • | 1.7 L diesel engine. Refer to Air Cleaner Assembly Replacement . |
| • | 2.0 L diesel engine. Refer to Air Cleaner Assembly Replacement . |
Note: DO NOT open hydraulic power steering system. |
| 2. | If equipped, loosen the power steering fluid reservoir and lay aside. Refer to Power Steering Fluid Reservoir Replacement . |
| 3. | Remove the brake booster bolts (1). |
Note:
|
| 4. | Pull the brake booster and the BPMV assembly forward in order to get access to the brake pedal bracket nuts (1). |
| 5. | Remove the brake pedal bracket nuts (1). |
| 6. | Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side . |
| 7. | Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement . |
| 8. | Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement . |
| 9. | Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement . |
| 10. | Remove the steering column. Refer to Steering Column Replacement . |
| 11. | Disconnect the brake pedal pushrod (1) from the brake pedal with brake pedal applied a bit. |
| 12. | Replace the click fit connector (1) between booster pushrod and brake pedal with new part. |
| 13. | Remove the clutch master cylinder nuts (2) from the pedal bracket, if equipped. |
| 14. | Disconnect the clutch master cylinder push rod (1) from the clutch pedal, if equipped. |
| 15. | Remove the brake pedal bracket bolt (1) from the tie bar. |
| 16. | Separate the wiring harness from the pedal bracket. |
| 17. | Disconnect the electrical connectors. |
| 18. | Remove the brake and accelerator and clutch pedal assembly from vehicle. |
| 19. | Transfer the component parts as needed. |
Installation Procedure
| 1. | Install the brake and accelerator and clutch pedal assembly to the vehicle. |
| 2. | Install the wiring harness to brake pedal bracket. |
| 3. | Connect the electrical connectors. |
Caution: Refer to Fastener Caution . |
| 4. | Install the brake pedal bracket bolts and tighten to 20N·m (15 lb ft) . |
| 5. | Connect clutch master cylinder push rod (1) to the clutch pedal, if equipped. |
| 6. | Install the clutch master cylinder nuts (2) to the pedal bracket, if equipped and tighten to 18 N·m (13 lb ft) . |
| 7. | Connect the brake pedal pushrod (1) to the brake pedal. |
| 8. | Install the steering column. Refer to Steering Column Replacement . |
| 9. | Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement . |
| 10. | Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement . |
| 11. | Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement . |
| 12. | Install the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side . |
Note: Second mechanic required. |
| 13. | Pull the brake booster and the BPMV assembly forward in order to gain access to the brake pedal bracket nuts (1). |
| 14. | Install the pedal bracket nuts (1) and tighten to 20 N·m (15 lb ft) . |
| 15. | Install the brake booster bolts (1) and tighten to 19 N·m (14 lb ft) . |
| 16. | If equipped, install the power steering fluid. Refer to Power Steering Fluid Reservoir Replacement . |
| 17. | Install the air cleaner assembly. Refer to: |
| • | 1.3 L diesel engine. Refer to Air Cleaner Replacement . |
| • | 1.4 L engine. Refer to Air Cleaner Assembly Replacement . |
| • | 1.6 L engine. Refer to Air Cleaner Assembly Replacement . |
| • | 1.7 L diesel engine. Refer to Air Cleaner Assembly Replacement . |
| • | 2.0 L diesel engine. Refer to Air Cleaner Assembly Replacement . |
| 18. | Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration . |
