Repair Procedures

Inspection

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

Standard value:
Stroke (A):
Gasoline 2.0, Diesel 1.6 :
145 ± 3 mm (5.7087 ± 0.1181 in.)
Gasoline 1.6 :
135 ± 3 mm (5.3150 ± 0.1181 in.)
Free play (B):6 - 13 mm (0.2362 - 0.5118 in.)
Height (C):189.1 mm (7.4449 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)





Removal

CAUTION:
- 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. Disconnect the push rod (C) from the clutch pedal by removing the snap pin (A) and washer (B).




2. Disconnect the ignition lock switch connector (C) and clutch switch connector (B).
3. Remove the clutch pedal mounting nuts (A-3ea).

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




4. Remove the clutch pedal.

Installation

1. Installation is in reverse order of removal.