GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 OUTLOOK - AWD 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Assembly Replacement

Removal Procedure
  1. Remove the left side instrument panel (I/P) insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.
  2. Remove the driver knee bolster. Refer to Driver Knee Bolster Replacement.
  3. Remove the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement.

    4. Object Number: 1862122 Size: SH
  4. Disconnect the brake pedal position sensor electrical connector (1).
  5. Remove the 2 brake pedal bracket bolts (2).

    6. Object Number: 1862124 Size: SH
  6. Remove the brake pedal pushrod retainer (1).

    7. Object Number: 1862126 Size: SH
  7. Remove the brake pedal pushrod clevis pin.
  8. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement.

    9. Object Number: 1862128 Size: SH
  9. Remove the 4 vacuum booster nuts.
  10. Position the vacuum brake booster and master cylinder assembly forward slightly to allow the brake pedal and bracket assembly to clear the booster studs.
  11. Remove the brake pedal assembly.

Installation Procedure

    Object Number: 1862128 Size: SH
  1. Position the brake pedal assembly to the dash panel.
  2. Position the vacuum brake booster and master cylinder assembly to the dash panel.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the 4 vacuum booster nuts.

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


    Object Number: 1862126 Size: SH
  4. Position the brake pedal pushrod to the brake pedal.
  5. Install the brake pedal pushrod clevis pin.

    6. Object Number: 1862124 Size: SH
  6. Install the brake pedal pushrod retainer (1).
  7. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement.

    8. Object Number: 1862122 Size: SH
  8. Install the 2 brake pedal bracket bolts (2).

    9. Tighten
    Tighten the bolts to 22 N·m (16 lb ft).

  9. Connect the brake pedal position sensor electrical connector (1).
  10. Connect the brake pedal position sensor electrical connector.
  11. Install the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement.
  12. Install the driver knee bolster. Refer to Driver Knee Bolster Replacement.
  13. Install the left side I/P insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.
  14. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.