Clutch pedal (LHD model)
Components Removal / installation
CLUTCH
CLUTCH PEDAL (LHD MODEL)
EXPLODED VIEW
REMOVAL
1. Disconnection of battery ground terminal (refer to 
)
)2. Removal of instrument side panel LH (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. Removal of power steering computer (refer to )
)
7. Disconnection of steering intermediate shaft ASSY
8. Removal of clutch pedal support SUB-ASSY
(1) Disconnect the 3 connectors.
(2) Remove the connector and wiring harness clamp.
(3) Remove the clip and push rod clevis pin to remove the clutch master cylinder push rod clevis from the clutch pedal lever SUB-ASSY.
(4) Remove the clip and push rod pin to remove the brake master cylinder push rod clevis from the brake pedal.
(5) Remove 2 nuts to remove the clutch master cylinder ASSY.
9. Removal of clutch start switch ASSY (refer to )
)
10. Removal of clutch switch ASSY
(1) Remove the nut and then remove the clutch switch ASSY from the clutch pedal support SUB-ASSY.
11. 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.
(3) Remove the 2 bushings from the clutch pedal SUB-ASSY and clutch pedal support SUB-ASSY.
12. Removal of clutch pedal SUB-ASSY
(1) Use a pin punch and hammer to drive in a pin and remove the clutch pedal lever SUB-ASSY.
(2) Remove the clutch pedal SUB-ASSY and 2 clutch pedal bushings from the clutch pedal support SUB-ASSY.
13. Removal of clutch pedal stopper
(1) Remove the clutch pedal stopper from the clutch pedal SUB-ASSY.
14. Removal of clutch pedal cushion No.1
(1) Remove the clutch pedal cushion No.1 from the clutch pedal SUB-ASSY.
15. 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.1
(1) Install the clutch pedal cushion No.1 to the clutch pedal SUB-ASSY.
3. Installation of clutch pedal stopper
(1) Install the clutch pedal stopper to the clutch pedal SUB-ASSY.
4. Installation of clutch pedal SUB-ASSY
(1) Apply NIGTIGHT LYW No.2 grease or equivalent to the inner and outer surfaces of the 2 clutch pedal bushings.
Captions in illustration
 |
NIGTIGHT LYW No.2 grease or equivalent |
(2) Install the clutch pedal SUB-ASSY and 2 clutch pedal bushings to the clutch pedal support SUB-ASSY.
(3) Align the holes of clutch pedal lever SUB-ASSY and clutch pedal SUB-ASSY, and drive in a pin using a pin punch and a hammer.
5. Installation of clutch pedal spring
(1) Install 2 bushings to the clutch pedal SUB-ASSY and clutch pedal support SUB-ASSY.
(2) Apply NIGTIGHT LYW No.2 grease or equivalent to the assist rod A, assist rod B, and clutch pedal spring outer surface.
Captions in illustration
|
|
NIGTIGHT LYW No.2 grease or equivalent |
(3) Install the assist rod A, assist rod B, clutch pedal spring, and assist bushing to the clutch pedal SUB-ASSY and clutch pedal support SUB-ASSY.
(4) 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 |
(5) Install 2 clutch clevis pins and 2 E-rings.
NOTE:
Insert the clutch clevis pin from the left side of the vehicle.
6. Installation of clutch switch ASSY
(1) Install the clutch switch ASSY to the clutch pedal support SUB-ASSY with the nut.
Standard value:
Standard value:
Tightening torque=8.0N·m
{
82kgf·cm}
{5.9ft·lbf}
7. Installation of clutch start switch ASSY (refer to )
)8. Installation of clutch pedal support SUB-ASSY
(1) Hang the hook for the clutch pedal support SUB-ASSY on the pedal bracket.
Captions in illustration
| *1 |
Hook |
(2) Install the clutch pedal support SUB-ASSY to the vehicle with 4 nuts and 3 bolts.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(3) Install to the clutch master cylinder ASSY with 2 nuts.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(4) Apply NIGTIGHT LYW No.2 grease or equivalent to the outer surfaces of a new push rod clevis pin.
(5) Install the clutch master cylinder push rod clevis to the clutch pedal lever SUB-ASSY with the push rod clevis pin and clip.
NOTE:
Install the push rod clevis pin from the left side of vehicle.
(6) Apply NIGTIGHT LYW No. 2 grease or equivalent to the inner and outer surfaces of a new push rod pin.
(7) Install the brake master cylinder push rod clevis with the push rod pin and clip.
NOTE:
Install the push rod from the left side of vehicle.
(8) Connect the connector and install the wiring harness clamp.
(9) Connect the 3 connectors.
9. Installation of steering intermediate shaft ASSY
(1) Install the steering intermediate shaft ASSY to the steering column ASSY.
Captions in illustration
| *a |
Alignment marks |
CAUTION:
Align the alignment marks of the steering intermediate shaft ASSY and steering column ASSY.
(2) Install the bolt.
Standard value:
Standard value:
Tightening torque=35N·m
{
357kgf·cm}
{25.8ft·lbf}
10. Check/adjustment of clutch pedal (refer to )
)
11. Check of clutch switch ASSY
12. Installation of power steering computer (refer to )
)13. Installation of knee airbag module (refer to )
)14. Installation of instrument panel under cover SUB-ASSY No.2 (refer to )
)15. Installation of instrument panel under cover SUB-ASSY No. 1 (refer to )
)16. Installation of instrument side panel LH (refer to )
)17. Check/adjustment of clutch pedal (refer to )
)18. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
19. Settings when removing/installing battery terminals (refer to )
)20. Check of clutch start system (refer to )
)21. Stop light check
(1) Check that the stop light illuminates when the brake pedal is depressed.
22. 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