CLUTCH PEDAL (for 1KD-FTV) ADJUSTMENT


  1. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (w/ Heater)


    1. Pull back the floor carpet.

    2. A01KH7NE02
      Text in Illustration
      *1 Clutch Switch Assembly
      *2 Adjusting Nut
      *3 Lock Nut
      *a Push Rod Play and Free Play Adjustment Point
      *b Pedal Free Play
      *c Pedal Height

      Check that the pedal height is correct.

      Pedal height from asphalt sheet
      168.5 to 178.5 mm (6.634 to 7.028 in.)

    3. If the pedal height is not as specified, adjust it as follows.


      1. Loosen the adjusting nut and turn the clutch pedal switch until the correct height is obtained.

      2. Tighten the lock nut.

        Torque:
        16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Check that the pedal free play and push rod play are correct.


      1. Depress the pedal until the clutch resistance begin 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.)
    5. A01KFWWE12
      Text in Illustration
      *a Push Rod Play
      *b Pedal Free Play

      Adjust the pedal free play and push rod play.


      1. Loosen the lock nut and turn the push rod until the free play and push rod play are correct.

      2. Tighten the lock nut.

      3. After adjusting the pedal free play, check the pedal height.

    6. A01KFTPE01
      Text in Illustration
      *a Full Stroke End Position
      *b 25 mm (0.984 in.) or more
      *c Release Point

      Check the clutch release point.


      1. Pull the parking brake lever and chock the wheels.

      2. Start the engine and allow it to idle.

      3. Without depressing the clutch pedal, slowly move the shift lever into the reverse position until the gears engage.

      4. Gradually depress the clutch pedal and measure the stroke distance form the point the gear noise stops (release point) to the full stroke end position.

        Standard distance
        25 mm (0.984 in.) or more (From pedal stroke end position to release point)

        If the distance is not as specified, perform the following operations.


        • Check the pedal height.

        • Check the push rod play and pedal free play.

        • Bleed the clutch line.

        • Check the clutch cover assembly and disc assembly.

  2. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (w/o Heater)


    1. Pull back the floor carpet.

    2. A01KEQCE02
      Text in Illustration
      *a Push Rod Play and Free Play Adjustment Point
      *b Pedal Height Adjustment Point
      *c Pedal Free Play
      *d Pedal Height

      Check that the pedal height is correct.

      Pedal height from asphalt sheet
      168.5 to 178.5 mm (6.634 to 7.028 in.)

    3. Adjust the pedal height.


      1. Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut.

        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    4. Check that the pedal free play and push rod play are correct.


      1. Depress the pedal until the clutch resistance begin 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.)
    5. A01KFWWE12
      Text in Illustration
      *a Push Rod Play
      *b Pedal Free Play

      Adjust the pedal free play and push rod play.


      1. Loosen the lock nut and turn the push rod until the free play and push rod play are correct.

      2. Tighten the lock nut.

      3. After adjusting the pedal free play, check the pedal height.

    6. A01KFTPE01
      Text in Illustration
      *a Full Stroke End Position
      *b 25 mm (0.984 in.) or more
      *c Release Point

      Check the clutch release point.


      1. Pull the parking brake lever and chock the wheels.

      2. Start the engine and allow it to idle.

      3. Without depressing the clutch pedal, slowly move the shift lever into the reverse position until the gears engage.

      4. Gradually depress the clutch pedal and measure the stroke distance form the point the gear noise stops (release point) to the full stroke end position.

        Standard distance
        25 mm (0.984 in.) or more (From pedal stroke end position to release point)

        If the distance is not as specified, perform the following operations.


        • Check the pedal height.

        • Check the push rod play and pedal free play.

        • Bleed the clutch line.

        • Check the clutch cover assembly and disc assembly.