Clutch Pedal Assembly: Service and Repair
CLUTCH PEDALCOMPONENTS:
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY LOWER
3. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER
4. DISCONNECT CONNECTOR
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 HOLE PIN
a. Remove the clip and hole pin.
7. REMOVE CLUTCH PEDAL SUPPORT SUBASSEMBLY
a. Remove the 2 nuts, bolt and clutch pedal support.
DISASSEMBLY
1. REMOVE CLUTCH START SWITCH ASSEMBLY
a. Remove the nut and clutch start switch.
2. REMOVE CLUTCH SWITCH ASSEMBLY
a. Remove the nut and clutch switch.
3. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING
a. Mount the clutch pedal in a soft jaw vise.
b. Using a screwdriver, remove the spring.
c. Remove the turn over bush from the clutch pedal.
4. REMOVE CLUTCH PEDAL TURN OVER BUSH
a. Using an 8 mm hexagon wrench and hammer, tap out the turn over bush.
5. REMOVE CLUTCH PEDAL SUB-ASSEMBLY
a. Remove the bolt and nut.
b. Remove the clutch pedal from the clutch pedal support.
6. REMOVE CLUTCH PEDAL PAD
7. REMOVE CLUTCH PEDAL BUSH
a. Remove the 2 bushes from the clutch pedal.
8. REMOVE NO. 1 CLUTCH PEDAL CUSHION
a. Using needle-nose pliers, remove the 2 cushions from the clutch pedal.
9. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
a. Using an 8 mm hexagon wrench and hammer, remove the clevis bush from the clutch pedal.
ADJUSTMENT
1. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
a. Turn back the floor carpet to expose the asphalt sheet under the pedal.
b. Check that the pedal height is correct.
Standard pedal height from asphalt sheet: 137.6 to 147.6 mm (5.417 to 5.811 inch)
c. Adjust the pedal height.
1. Loosen the lock nut and turn the stopper bolt until the correct height is obtained.
2. Tighten the lock nut.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
2. INSPECT PEDAL FREE PLAY AND PUSH ROD PLAY
a. Check that pedal free play and push rod play are correct.
1. Depress the pedal until clutch resistance begins to be felt.
Standard pedal free play: 5.0 to 15.0 mm (5.417 to 5.811 inch)
2. Gently depress the pedal until the resistance begins to increase a little.
Standard 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. Remove the No. 1 instrument panel airbag lower.
2. Loosen the lock nut and turn the push rod until correct free play and push rod play are obtained.
3. Tighten the lock nut.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
4. After adjusting the pedal free play, check the pedal height.
5. Install the No. 1 instrument panel airbag lower.
3. INSPECT CLUTCH RELEASE POINT
a. Check the clutch release point.
1. Pull the parking brake lever and use wheel chocks to secure the vehicle.
2. Start the engine and run it at idle.
3. Without depressing the clutch pedal, slowly move the shift lever into reverse until the gears contact.
4. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.
Standard distance: 25 mm or more (From pedal stroke end position to release point)
If the distance is not as specified, perform these operations.
^ Check the pedal height.
^ Check the push rod play and pedal free play.
^ Bleed air from the clutch line.
^ Check the clutch cover and disc.
REASSEMBLY
1. 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.
2. INSTALL NO. 1 CLUTCH PEDAL CUSHION
a. Using needle-nose pliers, install the 2 cushions to the clutch pedal.
3. 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.
4. INSTALL CLUTCH PEDAL PAD
5. 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.
6. INSTALL CLUTCH PEDAL TURN OVER 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.
7. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING
a. Apply MP grease to the inside of the turn over bush.
b. Install the turn over bush to the clutch pedal.
c. Install the spring to the clutch pedal and clutch pedal support.
8. INSTALL CLUTCH SWITCH ASSEMBLY
a. Install the clutch switch to the clutch pedal with the nut.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
9. INSTALL CLUTCH START SWITCH ASSEMBLY
a. Install the clutch start switch to the clutch pedal support with the nut.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
INSTALLATION
1. INSTALL CLUTCH PEDAL SUB-ASSEMBLY
a. Install the clutch pedal support to the vehicle with the 2 nuts and bolt.
Torque: 24 Nm (241 kgf-cm, 17 ft. lbs.) for bolt
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.) for nut
2. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS 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.
3. INSTALL CLUTCH PEDAL SPRING
4. CONNECT CONNECTOR
a. Connect the clutch start switch connector.
b. Connect the clutch switch connector.
5. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER
6. INSPECT AND ADJUST CLUTCH PEDAL SUBASSEMBLY
a. Inspect and adjust the clutch pedal.
7. INSTALL NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY LOWER
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. PERFORM INITIALIZATION
a. Perform initialization.
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
10. CHECK SRS WARNING LIGHT
a. Check SRS warning light.