CLUTCH PEDAL (for LHD) INSTALLATION


  1. INSTALL CLUTCH PEDAL PAD


    1. Install the clutch pedal pad onto the clutch pedal.

  2. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH


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

    2. A0118XH

      Using an 8 mm hexagon wrench and hammer, install the new clevis bush onto the clutch pedal.

  3. INSTALL NO. 1 CLUTCH PEDAL CUSHION


    1. A011A9Z

      Install the 2 No. 1 clutch pedal cushions onto the clutch pedal.

  4. INSTALL CLUTCH PEDAL SHAFT COLLAR

    A011BQAE01
    Text in Illustration
    *1 Clutch pedal bush
    *2 Clutch pedal shaft collar

    1. Apply MP grease to inside of the 2 clutch pedal bushes.

    2. Install the 2 clutch pedal bushes and clutch pedal shaft collar into the clutch pedal.

  5. INSTALL CLUTCH PEDAL SUB-ASSEMBLY


    1. A011AE1

      Install the clutch pedal with the clutch pedal shaft and nut.

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

  6. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING

    A011B0DE01
    Text in Illustration
    *1 Turn over spring seat compression spring
    *2 Clutch pedal spring holder
    *3 Clutch pedal turnover bush

    1. Apply MP grease onto the sliding portion of the clutch pedal spring holder.

    2. Apply MP grease onto the turn over spring seat compression spring and clutch pedal turnover bush.

    3. Install the clutch pedal turnover bush onto the clutch pedal.

    4. Install the turn over spring seat compression spring with the clutch pedal spring holder onto the clutch pedal.

    5. Install the clutch pedal spring holder onto the clutch pedal support.

  7. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING

    A0118GBE01
    Text in Illustration
    *1 Tension spring
    *2 Spring hook
    *3 No. 1 pedal spring hook

    1. Engage the 2 claws and install the No. 1 pedal spring hook.

    2. Apply MP grease to the tension spring and spring hook.

    3. Install the pedal with hook spring onto the clutch pedal and No. 1 pedal spring hook.

  8. TEMPORARILY TIGHTEN CLUTCH SWITCH ASSEMBLY


    1. A011940E01
      Text in Illustration
      *1 Turn
      *2 Adjusting nut

      Fully loosen the adjusting nut and temporarily tighten the clutch switch onto the clutch support.

      Note

      Do not fully tighten the adjusting nut, because the nut will be tightened after adjusting the height of the pedal.

  9. INSTALL CLUTCH START SWITCH ASSEMBLY


    1. A011BEE

      Install the clutch start switch with the nut onto the clutch pedal support.

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

  10. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY


    1. A0118P0E01
      Text in Illustration
      *1 Clip
      *2 Push rod clevis pin

      Install the clutch pedal support with the 2 nuts and bolt.

      Torque:
      Nut
      13 N*m  { 129 kgf*cm, 9 ft.*lbf }
      Bolt
      24 N*m  { 241 kgf*cm, 17 ft.*lbf }

    2. Apply MP grease to push rod clevis pin.

    3. Connect the clutch master cylinder push rod clevis to the clutch pedal support sub-assembly with the push rod clevis pin and a new clip.

    4. Connect the 2 connectors and install the wire harness clamps onto the clutch pedal assembly.

    5. A011B8RE01
      Text in Illustration
      *1 2.5 to 5.5 mm (0.098 to 0.217 in.)

      With the clutch pedal depressed to the fully open position, check that the clearance shown in the illustration is 2.5 to 5.5 mm (0.098 to 0.217 in.).

  11. INSPECT AND ADJUST CLUTCH PEDAL


    1. Pull back the floor carpet.

    2. A011AMUE02
      Text in Illustration
      *1 Clutch switch assembly
      *2 Adjust nut
      *a Clutch pedal height

      Check that the pedal height is correct.

      Pedal height from floor
      for 1KR-FE, 1NR-FE
      123.9 to 133.9 mm (4.878 to 5.272 in.)
      for 1ND-TV
      136.7 to 146.7 mm (5.382 to 5.776 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 adjusting nut.

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

  12. CHECK CLUTCH START SYSTEM


    1. Check that the engine does not start when the clutch pedal is released.

    2. Check that the engine starts when the clutch pedal is fully depressed.

      If necessary, inspect and replace the clutch pedal switch assembly Click here.

  13. INSTALL KNEE AIR BAG ASSEMBLY


    1. Install the knee air bag assembly Click here.