CLUTCH PEDAL (for RHD) 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

    A0118QQ

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

    2. Install the new clevis bush onto the clutch pedal.

      Tech Tips

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

  3. INSTALL NO. 1 CLUTCH PEDAL CUSHION

    A011A9Z

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

  4. INSTALL CLUTCH PEDAL SHAFT COLLAR

    A01170ME01
    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

    A0117VK

    1. 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 (for 1ND-TV)

    A0117C2E01
    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 NO. 1 PEDAL SPRING HOOK (for 1ND-TV)

    A0117IKE01
    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. A0119ODE01
      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

    A0119PG

    1. 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

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    1. Install the clutch pedal support onto the vehicle with the 2 bolts.

      Torque:
      24 N*m  { 241 kgf*cm, 17 ft.*lbf }

    2. Connect the clutch start switch connectors.

    3. A011B3SE01
      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. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY


    1. Install the clutch master cylinder assembly Click here.

  12. INSPECT AND ADJUST CLUTCH PEDAL


    1. Pull back the floor carpet.

    2. A01197XE02
      Text in Illustration
      *1 Clutch switch assembly
      *2 Adjusting nut
      *a Clutch pedal height

      Check that the pedal height is correct.

      Pedal height from floor
      for 1KR-FE, 1NR-FE
      124.9 to 134.9 mm (4.917 to 5.311 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 }

  13. 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.