Clutch Pedal Assembly: Service and Repair

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





Removal
1. Drain the clutch system brake fluid via the bleed nipple on the slave cylinder using bleed unit tool No. 88 19 096, or equivalent.
2. Disconnect the electrical connection to the anti-theft alarm's hood switch, if installed.
3. Remove the main fuse box and place it aside.





4. Disconnect the supply hose from the master cylinder.
5. Undo the clip securing the delivery pipe adjacent to the master cylinder.
6. Withdraw the delivery pipe.
7. From the engine bay, undo the nut securing the righthand part of the clutch pedal bracket to the bulkhead partition.





8. Remove the lower part of the dashboard below the steering wheel and knee shield.
9. Remove the floor air duct and pedal switch.





10. Remove the air duct leading to the side defroster and remove the cable tie on the wiring harness.





11. Remove the locking clip and pin from the clutch pedal.
12. Undo the nut securing the clutch pedal.
13. Lift out the righthand part of the clutch pedal bracket with master cylinder.
14. Undo the clip and remove the spring from the clutch pedal.
15. Slacken the nut below the dashboard.





16. Remove the nut securing the clutch pedal's lefthand bracket on the outside of the bulkhead partition.
17. Withdraw the bracket with clutch pedal.
18. Detach the clutch pedal from the bracket.

Installation
1. Mount the clutch pedal on the bolt.





2. Position and tighten the clutch pedal's lefthand bracket.
- Start with the nut in the engine bay.
- Tightening torque: 24 Nm (18 ft. lbs.).





3. Tighten the pedal bracket retaining nut below the dashboard to 24 Nm (18 ft. lbs.).
- Install the spring and clip on the clutch pedal.
4. Position the righthand part of the clutch pedal bracket with master cylinder on the bulkhead partition and the clutch pedal's bolt.
5. Install the nut on the clutch pedal bolt but do not tighten it.
6. Check that the clutch pedal spring is correctly installed.





7. Tighten the righthand part of the clutch pedal's bracket to the bulkhead partition.
- Tightening torque: 24 Nm (18 ft. lbs.) .
8. Connect the supply hose to the master cylinder.
9. Connect the delivery pipe and install the locking clip.





10. Install the main fuse box and reconnect the anti-theft alarm's hood switch.





11. Tighten the nut retaining the clutch pedal to 47 Nm (35 ft. lbs.).
12. Install the clutch pedal's pin and locking clip.





13. Install the air duct for the side defroster and secure the wiring harness.
14. Install the pedal switches.
15. Depress the pedal and pull out the switch pushrod.
- Adjust the switch to the correct position when the pedal is released.





16. Install the knee shield, floor air duct and lower dashboard section.
17. Top up the brake fluid.
18. Bleed the clutch hydraulic system.
19. Test the clutch and cruise control.