Click here

CLUTCH PEDAL (for LHD) INSTALLATION

Click here
Click here Click here
  1. Click here

    INSTALL CLUTCH PEDAL SPRING HOLDER


    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.

  2. Click here

    INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH


    1. Apply MP grease to the inside of a new clevis bush.

    2. Install the clevis bush to the clutch pedal.

      Tip:

      Install the clevis bush from the right side of the vehicle.

  3. Click here

    INSTALL CLUTCH PEDAL TURNOVER BUSH


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

    2. Install the clutch pedal turnover bush to the clutch pedal.

  4. Click here

    INSTALL NO. 2 CLUTCH PEDAL CUSHION


    1. Install the 2 clutch pedal cushions to the clutch pedal.

  5. Click here

    INSTALL CLUTCH PEDAL BUSH


    1. Apply MP grease to the inside and outside of 2 new bushes.

    2. Install the 2 bushes to the clutch pedal.

  6. Click here

    INSTALL CLUTCH PEDAL SHAFT COLLAR


    1. Apply MP grease to the clutch pedal shaft collar.

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

  7. Click here

    INSTALL CLUTCH PEDAL PAD


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

  8. Click here

    INSTALL CLUTCH PEDAL SUB-ASSEMBLY


    1. A0158AI

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

      34 N*m 350 kgf*cm 25 ft.*lbf
      Tip:

      Install the bolt from the right side of the vehicle.

    2. A015DREE01

      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.

  9. Click here

    INSTALL CLUTCH PEDAL SPRING


    1. Apply MP grease to the inside and outside of the spacer and pin of the clutch pedal support.

    2. Install the spacer to the spring.

    3. Install the spring to the clutch pedal support with 2 new E-rings.

  10. Click here

    INSTALL TURNOVER SPRING


    1. Apply MP grease to the contact surfaces of the spring holder, clutch pedal and spring.

    2. Move the pedal to the full stroke position.

    3. Install the spring to the clutch pedal and spring holder.

  11. Click here

    INSTALL CLUTCH PEDAL SUPPORT ASSEMBLY WITH CLUTCH MASTER CYLINDER


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

      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.

  12. Click here

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


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

      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.

  13. Click here

    INSTALL MAIN BODY ECU (COWL SIDE JUNCTION BLOCK LH)


    1. Connect the 9 ECU connectors.

    2. A015CNL

      Install the ECU with the 3 bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  14. Click here

    FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3
  15. Click here

    BLEED CLUTCH LINE


    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.

      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.

  16. Click here

    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.

        16 N*m 160 kgf*cm 12 ft.*lbf
    3. A015E07E03

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

      Tip:

      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.

      Tip:

      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.

        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.

  17. Click here

    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
  18. Click here

    INSPECT FOR CLUTCH FLUID LEAK

  19. Click here

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


    1. Attach the 2 claws and connect the DLC3.

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

  20. Click here

    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.

      10 N*m 102 kgf*cm 7 ft.*lbf
  21. Click here

    INSTALL NO. 1 SWITCH HOLE BASE


    1. Connect the connectors.

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

  22. Click here

    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. A015CUJ

        Install the 2 bolts.

    5. w/o Driver Side Knee Airbag:


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

      2. A015A9A

        Install the 2 bolts.

    6. A015ATT

      Attach the 2 claws to close the hole cover.

  23. Click here

    INSTALL COWL SIDE TRIM BOARD LH


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

    2. Install the cap nut.

  24. Click here

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


    1. Connect the connectors.

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

    3. Install the 2 screws.

  25. Click here

    INSTALL FRONT DOOR SCUFF PLATE LH


    1. Attach the 7 claws and 4 clips to install the scuff plate.

  26. Click here

    INSTALL NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH


    1. A0156L8E01

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

      Table 1. Text in Illustration
      *A w/ Entry and Start System *B w/o Entry and Start System
  27. Click here

    INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH


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

  28. Click here

    INSTALL INSTRUMENT SIDE PANEL LH


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

  29. Click here

    INSTALL LOWER INSTRUMENT PANEL PAD SUB-ASSEMBLY LH


    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.

  30. Click here

    INSTALL NO. 2 INSTRUMENT PANEL FINISH PANEL CUSHION


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