GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 SL1/SC1/SW1 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Assembly Replacement

Removal Procedure

    Object Number: 859447 Size: SH
  1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
  2. On sedans and wagons, remove the windshield defroster nozzle duct by rotating the front of the duct up and away from the windshield.

    3. On coupes, the windshield defroster nozzle duct cannot be removed because of the windshield rake angle. Push the windshield defroster duct as far as possible to the passenger side to gain access to the brake pedal.


    Object Number: 866729 Size: SH
  3. Remove the vacuum booster push rod retainer and washer.
  4. Remove the brake pedal pivot bolt and nut by accessing them through the top of the instrument panel.
  5. Remove the vacuum booster push rod from the brake pedal push rod pin.
  6. Remove the brake pedal from the vehicle.

Installation Procedure

    Object Number: 866731 Size: SH
  1. Position the brake pedal in the vehicle.
  2. Apply grease to the brake pedal push rod pin and place the vacuum booster push rod onto the pin.
  3. Install the brake pedal pivot bolt and nut by accessing them through the top of the instrument panel.

    4. Tighten
    Tighten the bolt to 22 N·m (16 lb ft).


    Object Number: 866729 Size: SH
  4. Install the vacuum booster push rod retainer and washer.
  5. Check and adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment .

    6. Object Number: 859447 Size: SH
  6. On sedans and wagons, install the windshield defroster nozzle duct into the vehicle by snapping the windshield defroster nozzle duct onto the mode valve assembly and install the screws.

    7. On coupes, move the windshield defroster nozzle duct from the passenger side and snap the windshield defroster nozzle duct onto the mode valve assembly and install the screws.

  7. Enable the SIR System. Refer to Enabling the SIR System in SIR.