Adjustable Pedal System: Removal & Installation Saturn Aura I

Removal Procedure

1. Remove the knee bolster. Refer to «Knee Bolster Replacement»(ref-301482-S02966914242008101700000) .
2. Remove the closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .
3. Remove the electrical connector from the brake apply sensor.
4. Remove the electrical connector from the brake pedal adjustment position sensor.
5. Remove the steering column assembly from the vehicle. Refer to «Steering Column Replacement (Electronic Power Steering)»(ref-301488-S18607570472008101700000) or «Steering Column Replacement (Hydraulic Power Steering)»(ref-301488-S22029566792008101700000) .
6. Remove the cable from the adjustable pedal assemblies. Refer to «Brake Pedal Adjuster Actuator Cable Replacement»(ref-301494-S20838347122008101700000) .
7. Remove the 2 brake pedal assembly to cowl mounting nuts.
8. Remove the booster pushrod retaining clip (1), the washers (2), and the booster pushrod (3) from the adjustable pedal pivot pin (4).
9. Remove the 3 brake pedal assembly to instrument panel (I/P) carrier bolts.
10. Remove the adjustable brake pedal assembly from the vehicle.

Installation Procedure

1. Insert a #4 square drive tool into the adjustable brake pedal actuator assembly and turn until the adjustable brake pedal assembly moves fully rearward.
2. Install the adjustable brake pedal assembly to the vehicle.
3. Install the 3 brake pedal assembly to I/P carrier bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the 2 brake pedal assembly to cowl mounting nuts. Tighten: Tighten the nuts to 15 N.m (11 lb ft).
5. Install the booster pushrod retaining clip (1), the washers (2), and the booster pushrod (3) to the adjustable pedal pivot pin (4).
6. Install the steering column assembly to the vehicle. Refer to «Steering Column Replacement (Electronic Power Steering)»(ref-301488-S18607570472008101700000) or «Steering Column Replacement (Hydraulic Power Steering)»(ref-301488-S22029566792008101700000) .
7. Install the NEW cable. Refer to «Brake Pedal Adjuster Actuator Cable Replacement»(ref-301494-S20838347122008101700000) .
8. Install the electrical connector to the brake pedal adjustment position sensor.
9. Install the electrical connector to the brake apply sensor.
10. Install the closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .
11. Install the knee bolster. Refer to «Knee Bolster Replacement»(ref-301482-S02966914242008101700000) .
12. Calibrate the brake pedal position sensor. Refer to «Brake Pedal Position Sensor Calibration»(ref-301486-S29799087272008101700000) .

1. Disconnect the accelerator pedal position sensor electrical connector.
2. Remove the accelerator mounting nuts from the accelerator bracket.
3. Remove the accelerator assembly from the vehicle.

1. Install the accelerator assembly to the vehicle.
2. Install the accelerator mounting nuts to the accelerator bracket. Tighten: Tighten the nuts to 10 N.m (89 lb in).
3. Connect the accelerator pedal position sensor electrical connector.
4. Confirm that the accelerator sensor connector locking clip is fully secured.
5. Verify the operation of the accelerator pedal.

1. Remove the accelerator pedal from the vehicle. Refer to «Accelerator Pedal Assembly Replacement»(ref-301494-S17073028272008101700000) .
2. Remove the adjustable brake pedal cable. Refer to «Brake Pedal Adjuster Actuator Cable Replacement»(ref-301494-S20838347122008101700000) .
3. Remove the 3 nuts that attach the adjustable accelerator bracket to the cowl.
4. Remove the adjustable accelerator bracket from the vehicle.

1. Install the adjustable accelerator bracket to the vehicle.
2. Install the 3 adjustable accelerator bracket nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
3. Install the NEW cable. Refer to «Brake Pedal Adjuster Actuator Cable Replacement»(ref-301494-S20838347122008101700000) .
4. Install the accelerator pedal to the vehicle. Refer to «Accelerator Pedal Assembly Replacement»(ref-301494-S17073028272008101700000) .
5. Calibrate the brake pedal position sensor. Refer to «Brake Pedal Position Sensor Calibration»(ref-301486-S29799087272008101700000) .

1. Remove the adjustable accelerator pedal bracket assembly from the vehicle. Refer to «Accelerator Pedal Bracket Replacement»(ref-301494-S01665144152008101700000) .
2. Remove the 3 motor assembly screws and remove the motor assembly from the adjustable accelerator bracket.

1. Install the motor assembly to the adjustable accelerator bracket assembly.
2. Install the 3 screws to the adjustable accelerator bracket assembly. Tighten: Tighten the screws to 2 N.m (18 lb in).
3. Install the adjustable accelerator pedal bracket assembly to the vehicle. Refer to «Accelerator Pedal Bracket Replacement»(ref-301494-S01665144152008101700000) .

1. Remove the knee bolster. Refer to «Knee Bolster Replacement»(ref-301482-S02966914242008101700000) .
2. Remove the closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .
3. Use a flat-bladed tool to release the locking tabs from both cable ends.
4. Remove the cable from the adjustable brake pedal motor assembly.
5. Remove the cable from the adjustable brake pedal actuator assembly.

1. Insert a #2 square drive tool into the adjustable brake pedal actuator assembly and turn until the adjustable brake pedal assembly moves fully forward.
2. Install the NEW cable to the adjustable brake pedal actuator assembly and ensure the locking tabs of the cable are seated fully.
3. Cycle the adjustable pedal position switch until the adjustable accelerator pedal assembly is in a full forward position, toward the dash panel. This may take several attempts to ensure the proper position of the adjustable accelerator pedal assembly to the full forward position.
4. Install the NEW cable to the adjustable accelerator motor assembly. Ensure the locking tabs of the cable are seated fully.
5. Cycle the adjustable pedal position switch fully rearward and forward ensuring smooth and consistent operation of the adjustable pedals.
6. Install the closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .
7. Install the knee bolster. Refer to «Knee Bolster Replacement»(ref-301482-S02966914242008101700000) .
8. Rehome the brake pedal position sensor. Refer to «Brake Pedal Position Sensor Calibration»(ref-301486-S29799087272008101700000) .

1. Remove the instrument panel (I/P) closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .
2. Carefully cut and remove the tie strap securing the adjustable pedal module to the I/P support beam.
3. Remove the adjustable pedal module (1) from the side of the I/P support beam.
4. Disconnect the electrical connector from the adjustable pedal module.

1. Remove the old 2-sided tape from the I/P support beam.
2. If reinstalling the same adjustable pedal module, install NEW 2-sided tape to the module.
3. Connect the electrical connector to the adjustable pedal module.
4. Install the adjustable pedal module (1) to the side of the I/P support beam.
5. Install a NEW tie strap to secure the adjustable pedal module to the I/P support beam.
6. Install the closeout panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .

1. Remove the instrument panel insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .
2. Remove the intermediate steering shaft bolt and position the intermediate steering shaft away from the steering column in order to gain access to the brake pedal adjustment position sensor. Refer to «Intermediate Steering Shaft Replacement»(ref-301488-S24297822742008101700000) .
3. Disconnect the electrical connector from the brake and accelerator pedal adjustment position sensor.
4. Remove the brake and accelerator pedal adjustment position sensor bolt (1) and sensor (2).

1. Install the brake and accelerator pedal adjustment position sensor (2) to the brake pedal bracket. Ensure the brake pedal position sensor tab locks into the brake pedal bracket and the sensors arm is correctly installed.
2. Install the brake pedal adjustment position sensor bolt (1). Tighten: Tighten the bolt to 2 N.m (18 lb in).
3. Connect the electrical connector to the brake and accelerator pedal adjustment position sensor.
4. Install the intermediate steering shaft to the steering column. Refer to «Intermediate Steering Shaft Replacement»(ref-301488-S24297822742008101700000) .
5. Install the instrument panel insulator panel. Refer to «Instrument Panel Insulator Panel Replacement - Left Side»(ref-301482-S17362928362008101700000) .