Repair Procedures

Inspection

Clutch Pedal Inspection
1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis pin play (measured at the face of the pedal pad.)

Standard value
Stroke (A): 145 ± 3mm (5.7087 ± 0.1181 in.)
Free play (B): 6 - 13 mm (0.2362 - 0.5118 in.)
Height (C): 167mm (6.5748 in.)





Ignition Lock Switch Inspection
1. Disconnect 2P-connector from a ignition lock switch.
2. Disconnect the ignition lock switch. (if you can install a tester with the switch fixed, this step can be omissible)
3. Check for continuity between terminals. (refer to the table below)

NOTE:
- If there is difference between what tested and the table above, replace the ignition lock switch with a new one.





Standard value
Full stroke (A): 12.0 ± 0.3mm (0.4724 ± 0.0118 in.)
ON-OFF point (B): 2.0 ± 0.3mm (0.0787 ± 0.0118 in)




4. If there is difference between what tested and the table above, replace the ignition lock switch with a new one.

Removal

NOTE:
Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off immediately with water.

1. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
2. Clamp the clutch master cylinder hose (A). If there is not enough room for clamping, you can also clamp the hose from the brake master cylinder side.
3. Disconnect the clutch master tube line (B) after removing the pin on the clutch master cylinder.




4. Disconnect the ignition lock switch connector (B) and clutch switch (A).
5. Remove the clutch pedal assembly mounting nut (C-3ea) and bolts (D).

Tightening torque:
9.8 - 14.7 N.m (1.0 - 1.5 kgf.m, 7.2 - 10.8 lb-ft)

6. Remove the clutch pedal and the master cylinder assembly together.






Installation

1. Installation is in reverse order of removal.
A. Perform bleeding air procedure in concentric slave cylinder after pouring the brake fluid.