Clutch Pedal Assembly: Service and Repair
CLUTCH PEDALCOMPONENTS (Part 1) (Without Turn Over):
COMPONENTS (Part 2) (With Turn Over):
ON-VEHICLE INSPECTION
1. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
(a) Turn over the floor carpet.
(b) Check that the pedal height is correct.
Pedal height from asphalt sheet:
without Turn over: 135.8 to 145.8 mm (5.346 to 5.740 in.)
with Turn over: 131.6 to 141.6 mm (5.182 to 5.575 in.)
(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 (245 kgf/cm, 18 ft. lbs.)
2. INSPECT AND ADJUST 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.
Pedal free play: 5.0 to 15.0 mm (0.197 to 0.591 in.)
(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 in.)
(b) Adjust the pedal free play and push rod play.
(1) Loosen the lock nut and turn the push rod until correct free play and push rod play are obtained.
(2) Tighten the lock nut.
Torque: 12 Nm (120 kgf/cm, 9 ft. lbs.)
(3) After adjusting the pedal free play, check the pedal height.
3. INSPECT AND ADJUST CLUTCH RELEASE POINT
(a) Check the clutch release point.
(1) Pull the parking brake lever and install a wheel stoppers.
(2) Start the engine and run 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 (0.98 in.) 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. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER
2. REMOVE CLUTCH PEDAL SPRING (WITHOUT TURN OVER)
3. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN
(a) Remove the clip and hole pin.
4. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
(a) with Cruise control:
Disconnect the clutch switch assembly connector.
(b) Disconnect the clutch start switch assembly connector.
(c) Remove the 2 nuts, bolt and clutch pedal support assembly.
5. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING (WITH TURN OVER)
(a) Mount the clutch pedal in a soft jaw vise.
(b) Using a screwdriver, remove the spring.
6. REMOVE CLUTCH PEDAL TURNOVER BUSH (WITH TURN OVER)
7. REMOVE CLUTCH PEDAL SUB-ASSEMBLY
(a) Remove the bolt and nut.
(b) Remove the clutch pedal sub-assembly from the clutch pedal support.
8. REMOVE CLUTCH PEDAL PAD
9. REMOVE CLUTCH PEDAL BUSH
(a) Remove the 2 bushes from the clutch pedal.
10. REMOVE NO. 1 CLUTCH PEDAL CUSHION
(a) Using needle-nose pliers, remove the No. 1 cushion from the clutch pedal.
11. 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 sub-assembly.
INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
(a) Apply MP grease to 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 No. 1 cushion to the clutch pedal.
3. INSTALL CLUTCH PEDAL BUSH
(a) Apply MP grease to both side 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 sub-assembly 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 TURNOVER BUSH (WITH TURN OVER)
(a) Apply MP grease to inside of the turn over bush.
(b) Install the turn over bush to the clutch pedal sub-assembly.
7. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING (WITH TURN OVER)
(a) Apply MP grease to the contact surface of the bush and spring.
(b) Install the spring to the clutch pedal sub-assembly and clutch pedal support.
8. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
(a) Install the clutch pedal support to the vehicle with the 2 nuts and bolt.
Torque:
Bolt 19 Nm (195 kgf/cm, 14 ft. lbs.)
Nut 12 Nm (120 kgf/cm, 9 ft. lbs.)
(b) Connect the clutch start switch assembly connector.
(c) with Cruise control: Connect the clutch switch assembly connector.
9. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH 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 sub-assembly with the hole pin.
HINT: Install the hole pin from the right side of the vehicle.
(c) Install the clip to the hole pin.
10. INSTALL CLUTCH PEDAL SPRING (WITHOUT TURN OVER)
11. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER
12. INSPECT SRS WARNING LIGHT
13. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY