GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 RELAY 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Assembly Replacement

Removal Procedure
  1. Remove the left cowl side panel. Refer to Cowl Side Trim Panel Replacement .
  2. Remove the knee bolster. Refer to Knee Bolster Replacement .
  3. Disable the SIR system. Refer to SIR Disabling and Enabling .
  4. Disconnect the electrical connector from the stop lamp switch.
  5. Remove the booster push rod retain clip and washer (2) from the brake pedal assembly.
  6. Remove the accelerator pedal. Refer to Accelerator Pedal Position Sensor Replacement .

    7. Object Number: 180291 Size: SH
  7. Remove the booster push rod (2) from the brake pedal (1).
  8. Remove the brake booster mounting nuts (3).
  9. Remove the digital radio receiver and bracket, if equipped. Refer to Digital Radio Receiver Replacement .

    10. Object Number: 180294 Size: SH
  10. Remove the brake pedal brace (4) mounting nuts (1).
  11. Remove the brake pedal brace (4) mounting bolt.
  12. Remove the brake pedal assembly mounting nuts (2).
  13. Pull master cylinder and brake booster assembly forward for additional clearance while removing brake pedal assembly.
  14. Remove the brake pedal assembly with the bracket (4).
  15. Remove the brake pedal assembly (3) from the vehicle.
  16. Remove the brake pedal position sensor from the brake pedal assembly . Refer to Brake Pedal Position Sensor Replacement .

Installation Procedure
  1. Install the brake pedal position sensor to the brake pedal assembly. Refer to Brake Pedal Position Sensor Replacement .

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 180294 Size: SH
  2. Position the brake pedal brace (4) to the brake pedal assembly and install the brace mounting nuts (1).

    3. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  3. Install the brake pedal assembly (3) with the brace to the vehicle.
  4. Push the master cylinder and brake booster assembly back into position.
  5. Install the brake pedal brace (4) upper mounting bolt.

    6. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  6. Install the brake pedal assembly mounting nuts (2).

    7. Tighten
    Tighten the nuts (2) to 25 N·m (18 lb ft).

  7. Install the digital radio receiver and bracket, if equipped. Refer to Digital Radio Receiver Replacement .

    8. Object Number: 180291 Size: SH
  8. Install the brake booster mounting nuts (3).

    9. Tighten
    Tighten the nuts (3) to 25 N·m (18 lb ft).

  9. Install the booster push rod (2) to the brake pedal (1).
  10. Install washer and retain clip.
  11. Install the accelerator pedal. Refer to Accelerator Pedal Position Sensor Replacement .
  12. Enable the SIR system. Refer to SIR Disabling and Enabling .
  13. Connect the electrical connector to the stop lamp switch.
  14. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .
  15. Install the knee bolster. Refer to Knee Bolster Replacement .
  16. Install the left cowl side panel. Refer to Cowl Side Trim Panel Replacement .