Repair Procedures

Removal

1. Remove the flexible hose (A) from the brake reserve tank.




2. After pulling out a clip, disconnect the clutch tube (B) from the master cylinder.
3. Disconnect the ignition lock switch connector (A).




4. Remove the push rod from the clutch pedal by removing the snap pin (A) and washer (B).




5. Remove the clutch pedal mounting nut (C-3ea).
6. Remove the clutch pedal bracket mounting nut (A-2ea).




7. Remove the clutch master cylinder from the clutch pedal assembly by rotating the clutch master cylinder 45 degree counter clockwise.

Inspection

Clutch Pedal Assembly
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition lock switch inspection
Remove the ignition lock switch and check for continuity between the terminals. If the continuity is not as specified, replace the switch.





Standard value
Full stroke(A) : 12.0 ± 0.3mm (0.472 ± 0.012 in.)
ON-OFF point (B) : 2.0 ± 0.3mm (0.078 ± 0.012 in)





Installation

1. Install the clutch master cylinder to the clutch pedal assembly by rotating the clutch master cylinder 45 degree clockwise.
2. Install the clutch pedal bracket mounting nut (A-2ea).

Tightening torque :
13 - 16 Nm (1.3 - 1.6 kgf.m, 9.4 - 11.6 lb-ft)




3. Install the clutch pedal mounting nut (C-3ea).

Tightening torque :
13 - 16 Nm (1.3 - 1.6 kgf.m, 9.4 - 11.6 lb-ft)




4. Install the push rod to the clutch pedal by installing the snap pin (A) and washer (B).

Wheel bearing grease: SAE J310, NLGI No.2

5. Connect the ignition lock switch connector (A).




6. Install the flexible hose (A) to the brake reserve tank.




7. Connect the clutch tube (B) to the master cylinder and insert a clip.
8. Refill the brake fluid.
9. Bleed the air in the clutch system.