Step 1:
Remove Three 10mm nuts holding gas pedal to firewall:
Step 2:
Slide back red lock tab on connector:
Step 3:
Use flat head screw driver to press tab down inside of connector, and pull connector away from gas pedal assembly:
Step 4:
Take pedal assembly over to your workbench. Remove five TORX T-15 screws on electrical cover.
Step 5:
Remove electronic cover: Notice how the circuit board says REV 1.0? That means they haven't revised this gas pedal assembly since they first used it back in 2005!!! (My car is a 2008!)
Notice the circuit board with the wedge shaped carbon tracks. Notice the shiny marks on the tracks. See how they start slightly before the end of the gold track? That is your deadspace! Any movement before the very edge of the gold track will not be registered by the ECU!!!
THE ONLY WAY to fix this is mechanical adjustment. NO amount of tuning can remove this deadspace, it's simply impossbile!
Step 6:
Look at the pedal assembly. Notice the metal tabs and fine wire brushes? These are what we want to modify.
Very carefully, bend the brushes up so that they don't have such a steep angular bend in their tips. I have already done this in these photos, so it's not apparent how sharp the bend in the wires were prior to me modifying them. They are like this _/ and you want them to be straighter so that they move closer to the edge of the brass/carbon track.
Using some fine pliers, carefully bend the tips of the wires. These are VERY fine wires, be very careful.
Now bend the entire metal tabs up very slightly to compensate for the change in angle at the tips of the wires.
More pictures of the wires:
Another shot of the circuit board:
Notice that by bending the wires, we are moving them closer to the edge of the carbon/gold seam. This removes the dead space.
Step 7:
Put the cover back onto the pedal assembly. NOTE: There is a rubber gasket that goes in the slot. MAKE SURE not to lose it, or crush it, this could cause your vehicle to accelerate uncontrolably! Screw the 5 TORX screws back in VERY CAREFULLY do not distort the cover, or you may bend the wires and cause bad ju ju.
Re-install the pedal, and enjoy your new dead space free throttle!
I am not responsible if you ruin your 50$ gas pedal assembly by breaking off the fine wires, or over bending them.