CLUTCH PEDAL (for RHD) INSTALLATION

INSTALL CLUTCH PEDAL PAD
1. Install the clutch pedal pad to the clutch pedal sub-assembly.
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.
  
  Text in Illustration
  
  MP grease
2. Install the clutch master cylinder push rod clevis bush to the clutch pedal sub-assembly.
INSTALL NO. 1 CLUTCH PEDAL CUSHION
1. Install the 2 No. 1 clutch pedal cushions to the clutch pedal sub-assembly.

Text in Illustration
	MP grease

INSTALL CLUTCH PEDAL SHAFT COLLAR

Text in Illustration
*1	Clutch Pedal Bush
*2	Clutch Pedal Shaft Collar
	MP grease

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

Install the 2 clutch pedal bushes and the clutch pedal shaft collar to the clutch pedal sub-assembly.

INSTALL CLUTCH PEDAL SUB-ASSEMBLY
1. 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 }
  
  Note
  
  Turn the nut while holding the bolt.

INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING (for 1NR-FE)

Text in Illustration
*1	Turn Over Spring Seat Compression Spring
*2	Clutch Pedal Spring Holder
*3	Clutch Pedal Turnover Bush
	MP grease

Apply MP grease to the contact surface of the clutch pedal spring holder and the clutch pedal support sub-assembly.

Apply MP grease to the contact surface of the turn over spring seat compression spring and a new clutch pedal turnover bush.
Install the clutch pedal turnover bush to the clutch pedal sub-assembly.
Install the turn over spring seat compression spring with the clutch pedal spring holder to the clutch pedal sub-assembly.
Install the clutch pedal spring holder to the clutch pedal support sub-assembly.

INSTALL PEDAL SPRING WITH HOOK (for 1NR-FE)

Text in Illustration
*1	Tension Spring
*2	Spring Hook
*3	No. 1 Pedal Spring Hook
	MP grease

Engage the 2 claws and install the No. 1 pedal spring hook to the clutch pedal support sub-assembly.

Apply MP grease to the contact surface of the tension spring and the spring hook.
Apply MP grease to the contact surface of the tension spring and the No. 1 pedal spring hook.
Install the pedal spring with hook to the clutch pedal sub-assembly and the No. 1 pedal spring hook.

TEMPORARILY TIGHTEN CLUTCH SWITCH ASSEMBLY
1. Fully loosen the adjusting nut and temporarily tighten the clutch switch assembly to the clutch pedal support sub-assembly.
  Note
  
  To prevent damage, make sure to loosen the adjusting nut before attempting to rotate the clutch switch assembly.
  
  Do not fully tighten the adjusting nut, because the nut will be tightened after adjusting the height of the pedal.
INSTALL CLUTCH START SWITCH ASSEMBLY
1. Install the clutch start switch assembly to the clutch pedal support sub-assembly with the nut.
  
  Torque:
  
  16 N*m { 160 kgf*cm, 12 ft.*lbf }
  
  Note
  
  To prevent damage, do not rotate the clutch start switch assembly.
INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
1. Install the clutch pedal support sub-assembly with the 2 bolts.
  
  Torque:
  
  24 N*m { 241 kgf*cm, 17 ft.*lbf }
2. Connect the clutch start switch connector and engage the wire harness clamps to the clutch pedal support subassembly.
3. Text in Illustration
  
  *a Clearance
  
  Fully depressed
  
  With the clutch pedal fully depressed, check that the clearance shown in the illustration is as specified.
  
  Standard clearance
  
  2.5 to 5.5 mm (0.0985 to 0.216 in.)
INSTALL CLUTCH MASTER CYLINDER ASSEMBLY

Click here
INSPECT AND ADJUST CLUTCH PEDAL

Click here
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.

Text in Illustration
*a	Clearance
	Fully depressed