Clutch Pedal Assembly: Service and Repair
CLUTCH PEDALComponents:
ON-VEHICLE INSPECTION
1. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
a) Turn back the floor carpet.
b) Check that the pedal height is correct.
Pedal height from asphalt sheet: 173.1 to 183.1 mm (6.8149 to 7.2086 inch)
c) Adjust pedal height.
1) Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
2. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH ROD PLAY
a) Check that the pedal free play and push rod play are correct.
1) Depress the pedal until clutch resistance is felt.
Pedal free play: 5.0 to 15.0 mm (0.197 to 0.591 inch)
2) Gently depress the pedal until the resistance begins to increase a little.
Push rod play at pedal top: 1.0 to 5.0 mm (0.039 to 0.197 inch)
b) Adjust the pedal free play and push rod play.
1) Loosen the lock nut and turn the push rod until the free play and push rod play are correct.
2) Tighten the lock nut.
3) After adjusting the pedal free play, check the pedal height.
4) Connect the air duct and install the lower finish panel.
3. INSPECT CLUTCH RELEASE POINT
a) Check the clutch release point.
1) Pull the parking brake lever and install the wheel stopper.
2) Start and idle the engine.
3) Without depressing the clutch pedal, slowly move the shift lever to the reverse position until the gears are engaged.
4) Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) to the full stroke end position.
Standard distance: 25 mm (0.98 inch) or more (From pedal stroke end position to release point)
If the distance is not as specified, perform the following operations:
^ Check pedal height.
^ Check push rod play and pedal free play.
^ Bleed the clutch line.
^ Check the clutch cover assembly and disc assembly.
REMOVAL
1. PRECAUTION
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment.
3. REMOVE FRONT DOOR SCUFF PLATE LH (w/o Illumination)
4. REMOVE FRONT DOOR SCUFF PLATE LH (w/Illumination)
5. REMOVE FRONT DOOR OPENING TRIM COVER LH
6. REMOVE SIDE INSTRUMENT PANEL LH
7. REMOVE NO.1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
9. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
10. DISCONNECT WIRE HARNESS
a) Disconnect the 3 connectors and clamp.
11. DISCONNECT CLUTCH RESERVOIR TUBE
a) Disconnect the clutch reservoir tube.
HINT: Use a container to catch the fluid.
12. DISCONNECT CLUTCH LINE
a) Using SST, disconnect the clutch line from the clutch master cylinder.
SST 09023-00101
HINT: Use a container to catch the fluid.
13. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a) Remove the 2 nuts, bolt and clutch pedal support.
14. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN
a) Remove the clip and pin.
15. REMOVE PEDAL WITH HOOK SPRING
a) While the clutch pedal is fully depressed, remove the hook spring.
16. REMOVE CLUTCH PEDAL SUB-ASSEMBLY
a) Remove the pedal shaft, nut, washer, and clutch pedal from the clutch pedal support.
17. REMOVE CLUTCH PEDAL SPRING HOLDER
a) Remove the clutch pedal spring holder from the clutch pedal support.
18. REMOVE CLUTCH PEDAL TURNOVER BUSHING
a) Remove the turnover bushing from the clutch pedal.
19. REMOVE CLUTCH PEDAL SHAFT COLLAR
a) Remove the 2 pedal bushings and pedal shaft collar from the clutch pedal.
20. REMOVE CLUTCH PEDAL CUSHION
a) Remove the 3 clutch pedal cushions.
21. REMOVE CLUTCH PEDAL PAD
a) Remove the clutch pedal pad from the clutch pedal.
22. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING
a) Using a 8 mm hexagon wrench and a hammer, remove the clevis bushing from the clutch pedal.
INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING
a) Apply MP grease to the inside of a new clevis bushing.
b) Install the clevis bushing to the clutch pedal.
HINT: Install the clevis bushing from the left side of the vehicle.
2. INSTALL CLUTCH PEDAL PAD
a) Install the clutch pedal pad to the clutch pedal.
3. INSTALL CLUTCH PEDAL CUSHION
a) Using needle-nose pliers, install the 3 clutch pedal cushions to the clutch pedal.
4. INSTALL CLUTCH PEDAL SHAFT COLLAR
a) Apply MP grease to the inner, outer and end surfaces of 2 new pedal bushings.
b) Install the clutch pedal shaft collar and 2 pedal bushings to the clutch pedal.
5. INSTALL CLUTCH PEDAL TURNOVER BUSHING
a) Apply MP grease to the inside of the turnover bushing.
b) Install the turnover bushing to the clutch pedal.
6. INSTALL CLUTCH PEDAL SUB-ASSEMBLY
a) Install the clutch pedal to the clutch pedal support with the pedal shaft, washer, and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
7. INSTALL CLUTCH PEDAL SPRING HOLDER
a) Apply MP grease to the inside of a new clutch pedal spring holder.
b) Install the clutch pedal spring holder.
8. INSTALL PEDAL WITH HOOK SPRING
a) Apply MP grease to the sliding portion of the spring.
b) Install the hook spring.
9. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN
a) Apply MP grease to the contact surface of the pin and clevis bushing.
b) Connect the clevis to the clutch pedal with the pin.
HINT: Install a pin from the left side of the vehicle.
c) Install the new clip to the pin.
10. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a) Install the clutch pedal support with the 2 nuts and bolt.
Torque: Bolt 24 Nm (242 kgf-cm, 17 ft. lbs.)
Nut 20 Nm (202 kgf-cm, 15 ft. lbs.)
11. CONNECT CLUTCH LINE
a) Using SST, connect the clutch line.
SST 09023-00101
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
12. CONNECT CLUTCH RESERVOIR TUBE
a) Connect the clutch reservoir tube.
13. INSTALL WIRE HARNESS
a) Connect the 3 connectors and clamp.
14. BLEED CLUTCH LINE
a) Fill the brake reservoir with the brake fluid and bleed the clutch system.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
15. CHECK FOR BRAKE FLUID LEAKAGE
HINT: Check for leakage in the clutch system.
16. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
17. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
18. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
19. INSTALL NO.1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
20. INSTALL SIDE INSTRUMENT PANEL LH
21. INSTALL FRONT DOOR OPENING TRIM COVER LH
22. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination)
23. INSTALL FRONT DOOR SCUFF PLATE LH (w/Illumination)
24. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL
25. CHECK BRAKE FLUID LEVEL IN RESERVOIR
26. PERFORM INITIALIZATION
Some systems need initialization after reconnecting the negative battery terminal.
27. INSPECT SRS WARNING LIGHT