Repair Procedures

Removal

1. Disconnect the push rod from the master cylinder by removing the snap pin (A), washer (B) and the bolts (C).

Tightening torque :
(C) 11.8 - 14.7N.m (1.2 - 1.5kgf.m, 8.7 - 10.9lb-ft)




2. Disconnect the two ignition lock switch connectors.
3. Remove the clutch pedal mounting bolts (A-2ea) and the bracket mounting nuts (B-3ea).

Tightening torque :
(A,B) 16.7 - 25.5N.m (1.7 - 2.6kgf.m, 12.3 - 18.8lb-ft)




4. Remove the clutch pedal assembly.

Inspection

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. Installation is reverse of removal.
2. Apply the specified grease to the clutch pedal and bushings.

Chassis grease: SAE J310a, NLGI No.1




3. Adjust the clutch pedal within the standard value, then secure by tightening the lock nut.

Standard value
Stroke (A) : 150 - 155mm (5.98 - 5.99in)
Free play (B) : 6 - 13 mm (0.24 - 0.51in)
Height (C) : 216mm (8.5in)




4. Refill the brake fluid.