CLUTCH PEDAL(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL CLUTCH PEDAL TURNOVER BUSH

    A004S5QE01
    Text in Illustration
    *a MP grease

    1. Install the clutch pedal turnover bush to the clutch pedal sub-assembly.

    2. Apply MP grease to the inside of the clutch pedal turnover bush.

  2. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING

    A004Q7TE01
    Text in Illustration
    *a MP grease

    1. Apply MP grease to the inside of a new clutch master cylinder push rod clevis bushing.

    2. Install the clutch master cylinder push rod clevis bushing to the clutch pedal sub-assembly.

      Tech Tips

      Install the clutch master cylinder push rod clevis bushing from the left side of the vehicle.

  3. INSTALL NO. 1 CLUTCH PEDAL CUSHION


    1. A004R4U

      Install the 2 No. 1 clutch pedal cushions to the clutch pedal sub-assembly.

  4. INSTALL CLUTCH PEDAL BUSHING

    A004N00E01
    Text in Illustration
    *a MP grease

    1. Apply MP grease to both sides of 2 new clutch pedal bushings.

    2. Install the 2 clutch pedal bushings to the clutch pedal sub-assembly.

  5. INSTALL CLUTCH PEDAL PAD


    1. Install the clutch pedal pad to the clutch pedal sub-assembly.

  6. INSTALL CLUTCH PEDAL SUB-ASSEMBLY


    1. A004PXM

      Install the clutch pedal sub-assembly to the clutch pedal support sub-assembly with the bolt and nut.

      Torque:
      37 N*m  { 375 kgf*cm, 27 ft.*lbf }

      Tech Tips

      Install the bolt from the right side of the vehicle.

  7. INSTALL NO. 1 PEDAL SPRING HOOK

    A004N7DE01
    Text in Illustration
    *a MP grease

    1. Apply MP grease to the contact surface of the No. 1 pedal spring hook.

    2. Install the No. 1 pedal spring hook.

  8. INSTALL CLUTCH PEDAL SPRING

    A004RQRE01
    Text in Illustration
    *a MP grease

    1. Apply MP grease to the contact surface of the spring hook.

    2. Install the clutch pedal spring.

  9. INSTALL CLUTCH PEDAL STOPPER BOLT


    1. A004TSZ

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

      Tech Tips

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

  10. INSTALL CLUTCH PEDAL SPRING HOLDER

    A004OIPE01
    Text in Illustration
    *a MP grease

    1. Apply MP grease to the contact surface of the clutch pedal spring holder.

    2. Install the clutch pedal spring holder to the clutch pedal support sub-assembly.

  11. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING

    A004Q5KE01
    Text in Illustration
    *a MP grease

    1. Apply MP grease to the contact surfaces of the clutch pedal and turn over seat compression spring.

    2. Install the turn over seat compression spring to the clutch pedal and clutch pedal spring holder.

  12. INSTALL CLUTCH START SWITCH ASSEMBLY

    A004R8K

    1. Install the clutch start switch assembly with the nut.

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

  13. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY (CLUTCH PEDAL STROKE SENSOR)

    Click here

  14. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY


    1. A004OTM

      Install the nut to the clutch pedal support sub-assembly.

    2. A004TJY

      Install the clutch pedal support sub-assembly with the 2 nuts and bolt.

      Torque:
      for bolt
      24 N*m  { 241 kgf*cm, 17 ft.*lbf }
      for nut
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

    3. Connect the clutch start switch assembly connector and brake pedal stroke sensor assembly (clutch pedal stroke sensor) connector.

  15. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN

    A004OIZE02
    Text in Illustration
    *A for 2WW
    *B for 1WW
    *a MP grease

    1. Apply MP grease to the contact surface of the clutch master cylinder push rod clevis with hole pin.

    2. Connect the clevis to the clutch pedal sub-assembly with the clutch master cylinder push rod clevis with hole pin.

      Tech Tips

      Install the clutch master cylinder push rod clevis with hole pin from the right side of the vehicle.

    3. Install a new clip to the clutch master cylinder push rod clevis with hole pin.

  16. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

    Click here

  17. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

    Click here

  18. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here