CLUTCH MASTER CYLINDER (for LHD) INSTALLATION


  1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY


    1. A0156O3

      Install the clutch master cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }
    2. A015600E01

      Apply MP grease to the contact surface of the clevis pin and clevis bush.

    3. Install the wave washer to the clevis pin.

    4. Connect the clevis of the master cylinder to the clutch pedal with the clevis pin.

    5. Install a new clip to the clevis pin.

  2. INSTALL CLUTCH START SWITCH ASSEMBLY

    A01556P

    1. Install the clutch start switch to the clutch pedal bracket, and then temporarily install the 2 nuts.

      Tech Tips

      The 2 nuts will be tightened to a torque specification in the "Adjust Clutch Start Switch Assembly" procedure.

  3. INSTALL CLUTCH MASTER CYLINDER TO WAY TUBE

    A0158ZG

    1. Using a union nut wrench, install the tube to the clutch master cylinder and clutch pedal support way.

      Torque:
      15 N*m  { 155 kgf*cm, 11 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.

  4. INSTALL CLUTCH RESERVOIR HOSE

    A015DY7

    1. Install the clutch reservoir hose to the clutch master cylinder and clutch pedal support way with 2 new clips.

      Note

      Connect the clutch reservoir hose so that it will not be twisted.

  5. INSTALL CLUTCH PEDAL SUPPORT ASSEMBLY WITH CLUTCH MASTER CYLINDER

    A0155JR

    1. Install the clutch pedal support with clutch master cylinder with the bolt and 2 nuts.

      Torque:
      for bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      for nut
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

    2. Connect the clutch start switch connector.

    3. w/ Cruise Control System:

      Connect the clutch switch connector.

  6. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE AND CLUTCH RESERVOIR TUBE

    A015CZN

    1. Using a union nut wrench, connect the flexible hose tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 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 reservoir tube with a new clip.

  7. INSTALL MAIN BODY ECU (COWL SIDE JUNCTION BLOCK LH)

    A015D8H

    1. Connect the 9 ECU connectors.

    2. A015CNL

      Install the ECU with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  8. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  9. BLEED CLUTCH LINE

    A015C3Z

    1. Remove the release cylinder bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  10. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY


    1. A015E0SE01

      Check that the clutch pedal height is correct.

      Standard Clutch Pedal Height from Tibia Pad
      162.7 to 172.7 mm (6.41 to 6.79 in.)

    2. Adjust the clutch pedal height.


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

        Torque:
        16 N*m  { 160 kgf*cm, 12 ft.*lbf }
    3. A015E07E03

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

      Tech Tips

      Pay close attention to the change in resistance to distinguish between pedal free play and push rod play while performing the inspection.


      1. Depress the clutch pedal until the clutch resistance begins to be felt.

        Standard Pedal Free Play
        5.0 to 15.0 mm (0.197 to 0.591 in.)

      2. Gently depress the clutch pedal until the resistance begins to increase a little.

        Standard Push Rod Play at Pedal Top
        1.0 to 5.0 mm (0.0394 to 0.197 in.)

    4. Adjust the clutch pedal free play and push rod play.

      Tech Tips

      The push rod play can be adjusted by changing the length of the push rod. Pedal free play changes together with push rod play.


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

        Note

        If pedal free play and push rod play are not within the standard range even after adjustment, inspect the related parts.

      2. Tighten the lock nut.

        Torque:
        12 N*m  { 120 kgf*cm, 9 ft.*lbf }

      3. After adjusting the clutch pedal free play and push rod play, check the clutch pedal height.

        Standard Clutch Pedal Height from Tibia Pad
        162.7 to 172.7 mm (6.41 to 6.79 in.)
    5. A015A0NE29

      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 to R until the gears engage.

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

        Standard Distance from Pedal Stroke End Position to Release Point
        20 mm (0.787 in.) or more

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


        • Check the clutch pedal height.

        • Check the push rod play and pedal free play.

        • Bleed the clutch line.

        • Check the clutch cover and disc.

  11. ADJUST CLUTCH START SWITCH ASSEMBLY


    1. A015AWF

      While depressing the clutch pedal, tighten the 2 nuts so that the clearance between the clutch pedal and clutch start switch is within the specification.

      Standard clearance between clutch pedal and clutch start switch
      4.1 to 6.1 mm (0.162 to 0.240 in.)
      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  12. CHECK FLUID LEVEL IN RESERVOIR


    1. Check the fluid level.

      If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  13. INSPECT FOR CLUTCH FLUID LEAK

  14. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY (w/o Driver Side Knee Airbag)

    A0158Q7

    1. Attach the 2 claws and connect the DLC3.

    2. Install the lower instrument panel with the 5 bolts.

  15. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (w/ Driver Side Knee Airbag)


    1. A01556EE01

      Connect the connector.

      Note

      When handling the airbag connector, take care not to damage the airbag wire harness.

    2. Install the driver side knee airbag with the 5 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  16. INSTALL NO. 1 SWITCH HOLE BASE

    A015DE6

    1. Connect the connectors.

    2. Attach the 4 claws to install the No. 1 switch hole base.

  17. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL


    1. Connect the connectors.

    2. A0158MF

      for Automatic Air Conditioning System:


      1. Attach the 2 claws to install the room temperature sensor.

    3. A0156SA

      Attach the 2 claws to connect the 2 control cables.

    4. w/ Driver Side Knee Airbag:


      1. Attach the 16 claws to install the lower No. 1 instrument panel finish panel.

      2. Install the 2 bolts.

        A015CUJ

    5. w/o Driver Side Knee Airbag:


      1. Attach the 9 claws to install the lower No. 1 instrument panel finish panel.

      2. Install the 2 bolts.

        A015A9A
    6. A015ATT

      Attach the 2 claws to close the hole cover.

  18. INSTALL COWL SIDE TRIM BOARD LH

    A0156SP

    1. Attach the 2 clips to install the cowl side trim board.

    2. Install the cap nut.

  19. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Floor Under Cover)

    A015B20

    1. Connect the connectors.

    2. Attach the 3 claws to install the No. 1 instrument panel under cover.

    3. Install the 2 screws.

  20. INSTALL FRONT DOOR SCUFF PLATE LH

    Tech Tips

    Use the same procedures described for the LH side.

  21. INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH


    1. Attach the 2 claws to install the No. 2 instrument cluster finish panel garnish.

      A0156L8E01
      Text in Illustration
      *A w/ Entry and Start System *B w/o Entry and Start System

  22. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH

    A01555F

    1. Attach the 3 claws to install the No. 1 instrument cluster finish panel garnish.

  23. INSTALL INSTRUMENT SIDE PANEL LH

    A0155HU

    1. Attach the 6 claws to install the instrument side panel.

  24. INSTALL LOWER INSTRUMENT PANEL PAD SUB-ASSEMBLY LH

    A015BUX

    1. Connect the connectors and attach the 2 clamps.

    2. Attach the 8 claws to install the lower instrument panel pad sub-assembly.

    3. Install the clip and screw.

  25. INSTALL NO. 2 INSTRUMENT PANEL FINISH PANEL CUSHION

    A0155LC

    1. Attach the 7 claws to install the No. 2 instrument panel finish panel cushion.