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Home >> Suzuki >> 2009 >> XL7 Premium, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake Control System And Diagnosis >> Repair Instructions >> Brake Pedal Assembly Replacement >> Installation Procedure
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Installation Procedure

Fig 1: Identifying Brake Pedal Bracket Bolts
G05469535Courtesy of SUZUKI OF AMERICA CORP.
  1. Install the accelerator pedal assembly to the brake pedal bracket. Refer to ACCELERATOR PEDAL POSITION SENSOR REPLACEMENT .
    Fig 2: Identifying Booster Studs And Brake Pedal Bracket Pilot Bushings
    G05469536Courtesy of SUZUKI OF AMERICA CORP.
  2. Install the brake pedal assembly into the vehicle, while guiding the brake pedal bracket pilot bushings into the foam insulator panel.
  3. Position the booster studs through dash panel.
    CAUTION: Refer to FASTENER NOTICE .
    Fig 3: Identifying Brake Pedal Bracket-To-Steering Column Bracket Bolt
    G05469537Courtesy of SUZUKI OF AMERICA CORP.
  4. Install the brake pedal bracket-to-steering column bracket bolt.

    Tightening torque 

    Tighten the bolt to 25 N.m (18 lb ft). 

  5. Loosely install the brake booster mounting nuts.
  6. Apply a thin coating of lithium grease to the pushrod pin on the brake pedal.
    Fig 4: Identifying Brake Booster Mounting Nuts
    G05469538Courtesy of SUZUKI OF AMERICA CORP.
  7. Connect the brake booster pushrod to the brake pedal.
  8. Install the washer and retaining clip to the brake pedal.
    Fig 5: Identifying Vacuum Brake Booster Mounting Nuts
    G05469539Courtesy of SUZUKI OF AMERICA CORP.
  9. Tighten the vacuum brake booster mounting nuts.

    Tightening torque 

    Tighten the nuts to 25 N.m (18 lb ft). 

    Fig 6: Identifying Steering Column Bracket To Cowl Nut
    G05469540Courtesy of SUZUKI OF AMERICA CORP.
  10. Install the steering column bracket to cowl nut.

    Tightening torque 

    Tighten the nuts to 25 N.m (18 lb ft). 

  11. Connect the brake pedal position sensor electrical connector.
    Fig 7: Identifying Accelerator Pedal Assembly Electrical Connector
    G05469541Courtesy of SUZUKI OF AMERICA CORP.
  12. Connect the accelerator pedal assembly electrical connector.