Clutch Pedal Assembly: Service and Repair
CLUTCH PEDAL SUB-ASSEMBLY (MTM)
REPLACEMENT
NOTICE: When disconnecting the battery terminal, initialize the system(s) shown after the terminal is reconnected.
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1
3. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER
4. DISCONNECT CONNECTORS
a. Disconnect the clutch start switch connector.
b. Disconnect the clutch switch connector.
5. REMOVE CLUTCH PEDAL SPRING
6. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
a. Remove the clip and hole pin.
7. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a. Remove the 2 nuts, bolt and clutch pedal support assembly.
8. REMOVE CLUTCH START SWITCH ASSEMBLY
a. Remove the nut and clutch start switch assembly.
9. REMOVE CLUTCH SWITCH ASSEMBLY
a. Remove the nut and clutch switch assembly.
10. REMOVE TURNOVER SPRING SEAT COMPRESSION SPRING
a. Mount the clutch pedal in a soft jaw vise.
b. Using a screwdriver, remove the spring.
11. REMOVE CLUTCH PEDAL TURNOVER BUSH
a. Remove the turn over bush from the clutch pedal.
12. REMOVE CLUTCH PEDAL TURNOVER BUSH
a. Using a 8 mm hexagon wrench and a hammer, remove the turn over bush.
13. REMOVE CLUTCH PEDAL SUB-ASSEMBLY
a. Remove the bolt and nut.
b. Remove the clutch pedal from the clutch pedal support.
14. REMOVE CLUTCH PEDAL PAD
15. REMOVE CLUTCH PEDAL BUSH
a. Remove the 2 bushes from the clutch pedal.
16. REMOVE CLUTCH PEDAL NO.1 CUSHION
a. Using needle-nose pliers, remove the 2 No.1 cushions from the clutch pedal.
17. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
a. Using a 8 mm hexagon wrench and a hammer, remove the clevis bush from the clutch pedal.
18. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
a. Apply MP grease to the inside of a new clevis bush.
b. Install the clevis bush to the clutch pedal.
HINT: Install the clevis bush from the right side of the vehicle.
19. INSTALL CLUTCH PEDAL NO.1 CUSHION
a. Using needle-nose pliers, install the 2 No.1 cushions to the clutch pedal.
20. INSTALL CLUTCH PEDAL BUSH
a. Apply MP grease to the inner, outer and end surfaces of 2 new bushes.
b. Install the 2 bushes to the clutch pedal.
21. INSTALL CLUTCH PEDAL PAD
22. INSTALL CLUTCH PEDAL SUB-ASSEMBLY
a. Install the clutch pedal to the clutch pedal support with the bolt and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
HINT: Install the bolt from the right side of the vehicle.
23. INSTALL CLUTCH PEDAL TURNOVER BUSH
a. Apply MP grease to the inside of a new turn over bush.
b. Install the turn over bush to the clutch pedal support.
24. INSTALL CLUTCH PEDAL TURNOVER BUSH
a. Apply MP grease to the inside of the turn over bush.
b. Install the turn over bush to the clutch pedal.
25. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING
a. Install the spring to the clutch pedal and clutch pedal support.
26. INSTALL CLUTCH SWITCH ASSEMBLY
a. Install the clutch switch assembly to the clutch pedal support sub-assembly with the nut.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
27. INSTALL CLUTCH START SWITCH ASSEMBLY
a. Install the clutch start switch assembly to the clutch pedal support sub-assembly with the nut.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
28. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a. Install the clutch pedal support to the vehicle with the 2 nuts and bolt.
Torque:
Bolt: 24 Nm (241 kgf-cm, 17 ft. lbs.)
Nut: 12 Nm (120 kgf-cm, 9 ft. lbs.)
29. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
a. Apply MP grease to the contact surface of the hole pin and clevis bush.
b. Connect the clevis to the clutch pedal with the hole pin.
HINT: Install the hole pin from the right side of the vehicle.
c. Install the clip to the hole pin.
30. INSTALL CLUTCH PEDAL SPRING
31. CONNECT CONNECTORS
a. Connect the clutch start switch connector.
b. Connect the clutch switch connector.
32. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER
33. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
34. INSTALL INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1
35. CONNECT BATTERY NEGATIVE TERMINAL
36. INSPECT SRS WARNING LIGHT