CLUTCH PEDAL INSTALLATION


  1. INSTALL CLUTCH PEDAL SPRING HOLDER


    1. A01BAJRE02

      Apply MP grease to the inside of a new clutch pedal spring holder.

      Text in Illustration
      A01BAZL MP grease

    2. Install the clutch pedal spring holder.

  2. INSTALL CLUTCH PEDAL PAD


    1. Install the clutch pedal pad to the clutch pedal.

  3. INSTALL CLUTCH PEDAL NO.1 CUSHION


    1. A01BFV4

      Using needle-nose pliers, install the clutch pedal No.1 cushion to the clutch pedal.

  4. INSTALL CLUTCH PEDAL SHAFT COLLAR


    1. A01BECGE07
      Text in Illustration
      *1 Clutch Pedal Bushing
      *2 Clutch Pedal Shaft Collar
      A01BAZL MP grease

      Apply MP grease to the inner, outer and end surfaces of 2 new clutch pedal bushings.

    2. Install the clutch pedal shaft collar and 2 clutch pedal bushings to the clutch pedal.

  5. INSTALL CLUTCH PEDAL SUB-ASSEMBLY


    1. A01BBP8E02
      Text in Illustration
      *a Matchmarks

      Align the matchmarks on the clutch pedal and clutch pedal support.

    2. Install the clutch pedal to the clutch pedal support with the pedal shaft, washer, and nut.

      Torque:
      34 N*m  { 350 kgf*cm, 25 ft.*lbf }

  6. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING


    1. A01BB4ME03

      Apply MP grease to the sliding portion of the spring.

      Text in Illustration
      A01BAZL MP grease

    2. Install the turn over spring seat compression spring.

  7. INSTALL CLUTCH PEDAL SPRING (for 2KD-FTV)


    1. A01BCZOE03
      Text in Illustration
      *a Sliding end
      A01BAZL MP grease

      Apply MP grease No.2 to the sliding portion of the spring.

    2. A01BHUCE03
      Text in Illustration
      *A for LHD
      *B for RHD

      Install the clutch pedal spring.

      Note

      Be sure to install the spring with its end facing upward.

    3. Install a new E-ring.

  8. INSTALL CLUTCH PEDAL STOPPER BOLT (w/o Clutch Pedal Switch Assembly)


    1. A01BCOW

      Install the clutch pedal stopper bolt together with the nut so that its end touches the clutch pedal No.1 cushion.

      Tech Tips

      Tighten the lock nut to the specified torque when adjusting the clutch pedal.

  9. INSTALL CLUTCH SWITCH ASSEMBLY (w/ Clutch Pedal Switch Assembly)


    1. Using a 14 mm union nut wrench, install the clutch switch assembly.

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    2. Connect the clutch switch connector.

  10. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY


    1. A01BAM3E01

      Aligning the clip (clutch pedal support side) with the hole of the bracket on the vehicle, install the clutch pedal support.

      Note

      Make sure that the clip (clutch pedal support side) is securely engaged in the hole of the bracket on the vehicle.

    2. A01BD7F

      Install the clutch pedal support with the bolt.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    3. A01BEKME02

      Apply MP grease to the sliding portions of the push rod clevis and clutch pedal.

      Text in Illustration
      A01BAZL MP grease

    4. Install the push rod clevis to the cutout of the pedal from the right side of the vehicle and push it downward.

      Note

      Check that the push rod cannot be turned 30° or more in order to confirm that the clevis is securely engaged in the pedal.

    5. w/ Clutch Pedal Switch Assembly:

      Connect the clutch switch connector and attach the wire harness clamp.

  11. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY


    1. A01BHS1

      Install the clutch master cylinder with the 2 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

  12. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT

    Click here

  13. INSTALL NO.1 AIR DUCT (for RHD)

  14. INSTALL WASHER TANK AND PUMP ASSEMBLY (for LHD)


    1. w/ Rear Wiper:

      Connect the 2 connectors and 2 washer hoses.

    2. w/o Rear Wiper:

      Connect the connector and washer hose.

    3. Attach the hose clamp.

    4. Install the windshield washer motor and pump assembly with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    5. Connect the connector to the windshield washer motor and pump assembly.

  15. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER


    1. Attach the 8 claws to install the instrument panel finish panel lower center.

  16. INSTALL SHIFTING HOLE COVER ASSEMBLY


    1. for Manual Transmission:

      Attach the 6 claws to install the shifting hole cover assembly.

    2. for Automatic Transmission:

      Attach the 8 claws to install the shifting hole cover assembly.

  17. INSTALL SHIFT LEVER KNOB

  18. INSTALL PARKING BRAKE HOLE COVER


    1. Attach the 6 claws to install the parking brake hole cover.

  19. INSTALL NO.1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. Attach the 3 claws to instrument panel under cover sub-assembly No. 1.

    2. Install the the 2 clips.

  20. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER


    1. Connect the fuel lid lock control cable and bonnet (hood) control cable assembly to the instrument panel finish lower.

    2. Attach the 4 clips to install the instrument panel finish panel lower.

    3. Install the 2 clips.

  21. CONNECT BATTERY NEGATIVE CABLE

  22. PERFORM INITIALIZATION

    Some systems need initialization when disconnecting the cable from the negative battery terminal. Click here