Clutch pedal (RHD model)
Components Removal / installation
CLUTCH
CLUTCH PEDAL (RHD MODEL)
EXPLODED VIEW
REMOVAL
1. Disconnection of battery ground terminal (refer to 
)
)2. Removal of instrument side panel RH (refer to )
)3. Removal of instrument panel under cover SUB-ASSY No.1 (refer to )
)4. Removal of instrument panel under cover SUB-ASSY No.2 (refer to )
)5. Removal of knee airbag module (refer to )
)
6. Disconnection of clutch master cylinder ASSY
(1) Disconnect the 2 connectors.
(2) Remove the clip from the push rod clevis pin.
(3) Remove the push rod clevis pin and disconnect the clutch master cylinder push rod clevis from the clutch pedal SUB-ASSY.
(4) Remove the 2 nuts, and then disconnect the clutch master cylinder ASSY from the clutch pedal support SUB-ASSY.
7. Removal of clutch pedal support SUB-ASSY
(1) Remove the bolts, and then remove the clutch pedal support SUB-ASSY.
8. Removal of clutch switch ASSY
(1) Remove the nut and then remove the clutch switch ASSY from the clutch pedal support SUB-ASSY.
9. Removal of clutch start switch ASSY
(1) Remove the wiring harness clamp and the nut, and then remove the clutch start switch ASSY from the clutch pedal support SUB-ASSY.
10. Removal of clutch pedal spring
(1) Remove the 2 E-rings and 2 clutch clevis pins.
(2) Remove the assist rod A, assist rod B, clutch pedal spring, and assist bushing.
11. Removal of clutch pedal SUB-ASSY
(1) Remove the bolt and the nut, and then remove the clutch pedal SUB-ASSY from the clutch pedal support SUB-ASSY.
12. Removal of clutch pedal shaft collar
(1) Remove the 2 clutch pedal bushings and the clutch pedal shaft collar from the clutch pedal SUB-ASSY.
13. Removal of clutch pedal cushion No.1
(1) Remove the 2 clutch pedal cushion No.1.
14. Removal of bushing
(1) Remove the 3 bushings.
15. Removal of clutch pedal cushion No.2
(1) Remove the clutch pedal cushion No.2 from the clutch pedal SUB-ASSY.
16. Removal of clutch pedal pad
(1) Remove the clutch pedal pad from the clutch pedal SUB-ASSY.
INSTALLATION
1. Installation of clutch pedal pad
(1) Install the clutch pedal pad to the clutch pedal SUB-ASSY.
2. Installation of clutch pedal cushion No.2
(1) Install the clutch pedal cushion No.2 to the clutch pedal SUB-ASSY.
3. Installation of bushing
(1) Install the 3 bushings.
4. Installation of clutch pedal cushion No.1
(1) Install the 2 clutch pedal cushion No.1.
5. Installation of clutch pedal shaft collar
6. Installation of clutch pedal SUB-ASSY
(1) Install the clutch pedal SUB-ASSY to the clutch pedal support SUB-ASSY with the bolt and the nut.
Standard value:
Standard value:
Tightening torque=30N·m
{
306kgf·cm}
{22.1ft·lbf}
7. Installation of clutch pedal spring
(1) Apply NIGTIGHT LYW No.2 grease or equivalent to the assist rod A, assist rod B, and assist spring outer surface.
Captions in illustration
 |
NIGTIGHT LYW No.2 grease or equivalent |
(2) Install the assist rod A, assist rod B, clutch pedal spring, and assist bushing.
(3) Apply NIGTIGHT LYW No.2 grease or equivalent to the outer surfaces of the 2 clutch clevis pins.
Captions in illustration
|
|
NIGTIGHT LYW No.2 grease or equivalent |
(4) Install 2 clutch clevis pins and 2 E-rings.
8. Installation of clutch start switch ASSY (refer to )
)9. Removal of clutch switch ASSY (refer to )
)10. Installation of clutch pedal support SUB-ASSY
(1) Install the clutch pedal support SUB-ASSY with the bolt.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
11. Installation of clutch master cylinder ASSY
(1) Install the clutch master cylinder ASSY to the clutch pedal support SUB-ASSY with the 2 nuts.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(2) Apply NIGTIGHT LYW No.2 grease or equivalent to the outer surfaces of a new push rod clevis pin.
(3) Connect the clutch master cylinder push rod clevis to the clutch pedal SUB-ASSY with the push rod clevis pin.
NOTE:
Install the push rod clevis pin from the right side of vehicle.
(4) Install the clip to the push rod clevis pin.
(5) Connect the 2 connectors.
12. Installation of knee airbag module (refer to )
)13. Installation of instrument panel under cover SUB-ASSY No.2 (refer to )
)14. Installation of instrument panel under cover SUB-ASSY No.1 (refer to )
)15. Installation of instrument side panel RH (refer to )
)16. Check/adjustment of clutch pedal (refer to )
)17. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
18. Settings when removing/installing battery terminals (refer to )
)19. Check of clutch start switch ASSY function (refer to )
)20. Check of airbag warning light (refer to )
)ADJUSTMENT
1. Check/adjustment of clutch pedal
(1) If the full stroke of the clutch pedal SUB-ASSY is out of the standard range, loosen the lock nut on the clutch switch and adjust the full stroke of the clutch pedal with the clutch switch.
Standard value:
Captions in illustration
| *1 |
Lock nut |
| *a |
Clutch pedal stroke |
Clutch pedal stroke
: 110 to 115 mm {4.331 to 4.528 in}
Standard value:
Tightening torque=8.0N·m
{
82kgf·cm}
{5.9ft·lbf}
CAUTION:
When adjusting the full stroke of clutch pedal SUB-ASSY, do not turn the clutch switch ASSY.
NOTE:
If the clutch switch ASSY cannot adjust the full stroke of clutch pedal SUB-ASSY to the specified value, adjust it by turning the master cylinder push rod.
(2) Loosen the push rod lock nut of the clutch master cylinder ASSY.
(3) Adjust the clutch master cylinder push rod by turning it.
Captions in illustration
| *a |
Stroke extended |
| *b |
Stroke contracted |
(4) Check that the clutch pedal SUB-ASSY contacts the clutch pedal stopper when the clutch pedal SUB-ASSY is at the full stroke.
(5) Check that the clutch pedal SUB-ASSY contacts the clutch switch side when the pedal is released.
(6) Turn the clutch master cylinder push rod to the contracting side until a clearance is created on the clutch switch side.
(7) Turn the clutch master cylinder push rod to the extending side until it contacts the clutch switch ASSY.
(8) Turn it additional 270° to the contracting side.
Captions in illustration
| *a |
Stroke extended |
| *b |
Stroke contracted |
(9) Move the push rod clevis pin from side to side to check that it operates smoothly.
(10) Tighten the clutch master cylinder push rod lock nut of the clutch master cylinder ASSY.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
(11) Depress the clutch pedal SUB-ASSY 2 or 3 times to check that the clutch pedal SUB-ASSY and release lever operate smoothly. If the clutch pedal SUB-ASSY and release lever do not operate smoothly, execute air bleeding of the clutch line.
(12) Measure the full stroke of the clutch pedal SUB-ASSY and confirm that it is within the standard value. If it is out of the standard value, adjust again.
Clutch pedal stroke
: 110 to 115 mm {4.331 to 4.528 in}
: 110 to 115 mm {4.331 to 4.528 in}
2. Check of clutch pedal SUB-ASSY
(1) Move the clutch pedal in the lateral direction with a force of approximately 10 N {1.0 kgf, 2.2 lbf} to check that the clutch pedal deflection is within the standard value.
Deflection of the clutch pedal
: 4.0mm {0.158in} or less
If the deflection exceeds the standard value, replace the clutch pedal SUB-ASSY.: 4.0mm {0.158in} or less