Chevrolet Sonic manuals
 

Chevrolet Sonic Repair Manual: Brake Pedal Assembly Replacement

Chevrolet Sonic Repair Manual / Chassis / Brakes / Hydraulic Brakes / Brake Pedal Assembly Replacement

Removal Procedure
  1. Remove the battery tray. Refer to Battery Tray Replacement.


  2. Remove the power vacuum brake booster bolts (1).

  3. Remove the brake pedal assembly upper nuts (1)

  4. Remove the brake pedal assembly lower nuts (1)
  5. Remove the steering column. Refer to Steering Column Replacement.


  6. Remove the brake pedal release bracket bolt (1).

  7. Remove the brake pedal release bracket bolts (1).

  8. Remove the brake pedal release bracket (1).
  9. Disconnect the brake pedal position sensor electrical connector.
  10. On manual transmission equipped vehicles, disconnect the clutch pedal position sensor electrical connector.

  11. On manual transmission equipped vehicles, disconnect the clutch master cylinder pushrod retainer (1). Refer to Clutch Master Cylinder Replacement


  12. On manual transmission equipped vehicles, remove the clutch master cylinder bolts (1) and position aside the clutch master cylinder (2) without disconnecting the clutch fluid pipe. Clutch Master Cylinder Replacement
  13. Position aside any wiring harnesses attached to the brake pedal assembly bracket, as necessary.

  14. Remove the left upper brake pedal assembly bolt (1).

  15. Remove the right upper brake pedal assembly bolt (1).

  16. Using a suitable tool, carefully cut off the 2 upper brake pedal assembly locating pins (1).
  17. Remove the brake pedal assembly from the vehicle.
  18. Remove any necessary components from the brake pedal assembly.
Installation Procedure
  1. Using a suitable tool, carefully cut off the 2 upper brake pedal assembly locating pins.
  2. Install any removed components from the brake pedal assembly.
  3. Install the brake pedal assembly to the vehicle.

    4. Caution:

    Refer to Fastener Caution.

  4. Install the brake pedal assembly lower nuts (1) and tighten to  19 Y (14 lb ft)

    .



    5. Caution:

    Refer to Fastener Caution.

  5. Install the brake pedal assembly upper nuts (1) and tighten to  19 Y (14 lb ft)

    .



  6. Install the right upper brake pedal assembly bolt (1) and tighten to  9 Y (80 lb in)

    .



  7. Install the left upper brake pedal assembly bolt (1) and tighten to  9 Y (80 lb in)

    .

  8. Reposition any wiring harnesses attached to the brake pedal assembly bracket, as necessary.

  9. On manual transmission equipped vehicles, install the clutch master cylinder bolts (1) and the clutch master cylinder (2). Refer to Clutch Master Cylinder Replacement.


  10. On manual transmission equipped vehicles, connect the clutch master cylinder pushrod retainer (1). Refer to Clutch Master Cylinder Replacement.
  11. On manual transmission equipped vehicles, connect the clutch pedal position sensor electrical connector.

  12. Install the brake pedal release bracket (1).

  13. Install the brake pedal release bracket bolts (1) and tighten to  22 Y (16 lb ft)

    .



  14. Install the brake pedal release bracket bolt (1) and tighten to  22 Y (16 lb ft)

    .

  15. Connect the brake pedal position sensor electrical connector.
  16. Install the steering column. Refer to Steering Column Replacement.


  17. Install the power vacuum brake booster bolts (1) and tighten to  19 Y (14 lb ft)

    .

  18. Install the battery tray. Refer to Battery Tray Replacement.
Front Brake Hose Replacement
Removal Procedure Warning: Refer to Brake Dust Warning. Warning: Refer to Brake Fluid Irritant Warning. Danger: Do not use a service jack to lift this vehicle. Li ...

Brake Pedal Position Sensor Calibration
Calibration Criteria Note: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will ca ...

Other materials:

Recommended Fuel
Use regular unleaded gasoline with a posted octane rating of 87 or higher. If the octane rating is less than 87, an audible knocking noise may be heard. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. If heavy knocking is heard when using gasoline with a higher ...

Body Waterleak Repair
Warning: If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in person ...

Fuel Pump Flow Control Module Replacement
Fuel Pump Flow Control Module Replacement Callout Component Name Preliminary Procedures Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection. Remove the right rear compartmen ...

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