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CLUTCH PEDAL (for LHD) INSTALLATION

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  1. Click here

    INSTALL CLUTCH PEDAL TURNOVER BUSH (except 1ZR-FAE)


    1. Install the clutch pedal turnover bush to the clutch pedal sub-assembly.

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

      Table 1. Text in Illustration
      *1 MP grease
  2. Click here

    INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING


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

      Table 2. Text in Illustration
      *1 MP grease

    2. Install the clutch master cylinder push rod clevis bushing to the clutch pedal sub-assembly.

      Tip:

      Install the clutch master cylinder push rod clevis bushing from the left side of the vehicle.

  3. Click here

    INSTALL NO. 1 CLUTCH PEDAL CUSHION


    1. A01IRVJ

      Install the 2 No. 1 clutch pedal cushions to the clutch pedal sub-assembly.

  4. Click here

    INSTALL CLUTCH PEDAL BUSHING


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

      Table 3. Text in Illustration
      *1 MP grease

    2. Install the 2 clutch pedal bushings to the clutch pedal sub-assembly.

  5. Click here

    INSTALL CLUTCH PEDAL PAD


    1. Install the clutch pedal pad to the clutch pedal sub-assembly.

  6. Click here

    INSTALL CLUTCH PEDAL SUB-ASSEMBLY


    1. A01ITQ4

      Install the clutch pedal sub-assembly to the clutch pedal support sub-assembly with the bolt and nut.

      37 N*m 375 kgf*cm 27 ft.*lbf
      Tip:

      Install the bolt from the right side of the vehicle.

  7. Click here

    INSTALL PEDAL SPRING HOOK (for 1AD-FTV, 2AD-FHV)


    1. Apply MP grease to the contact surface of the pedal spring hook.

      Table 4. Text in Illustration
      *1 MP grease

    2. Install the pedal spring hook.

  8. Click here

    INSTALL PEDAL WITH HOOK SPRING (for 1AD-FTV, 2AD-FHV)


    1. Apply MP grease to the contact surface of the hook spring.

      Table 5. Text in Illustration
      *1 MP grease

    2. Install the hook spring.

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    INSTALL CLUTCH PEDAL SPRING (for 1ZR-FAE)


    1. Apply MP grease to the sliding portions of the clutch pedal spring.

      Table 6. Text in Illustration
      *1 MP grease

    2. Install the clutch pedal spring.

  10. Click here

    INSTALL CLUTCH PEDAL STOPPER BOLT


    1. A01IRET

      Install the clutch pedal stopper bolt together with the nut so that its end touches the No. 1 clutch pedal cushion.

      Tip:

      Tighten the lock nut to the specified torque when adjusting the clutch pedal.

  11. Click here

    INSTALL CLUTCH PEDAL SPRING HOLDER (except 1ZR-FAE)


    1. Apply MP grease to the contact surface of the clutch pedal spring holder.

      Table 7. Text in Illustration
      *1 MP grease

    2. Install the clutch pedal spring holder to the clutch pedal support sub-assembly.

  12. Click here

    INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING (except 1ZR-FAE)


    1. Apply MP grease to the contact surfaces of the clutch pedal spring holder and turn over seat compression spring.

      Table 8. Text in Illustration
      *1 MP grease

    2. Install the turn over seat compression spring to the clutch pedal and clutch pedal spring holder.

  13. Click here

    INSTALL CLUTCH START SWITCH ASSEMBLY


    1. Install the clutch start switch assembly with the nut.

      16 N*m 160 kgf*cm 12 ft.*lbf
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    INSTALL CLUTCH SWITCH ASSEMBLY


    1. Install the clutch switch assembly with the nut.

      16 N*m 160 kgf*cm 12 ft.*lbf
    2. A01IQYBE01

      With the clutch pedal fully depressed, check the clearance.

      Standard Measurement
      Area Item Specified Condition
      a for 1AD-FTV, 2AD-FHV 0.2 to 3.2 mm (0.0079 to 0.126 in.)
      for 1ZR-FAE 2 to 5 mm (0.0787 to 0.197 in.)
      for 2ZR-FAE 1.1 to 4.1 mm (0.433 to 0.161 in.)
  15. Click here

    INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY


    1. A01INV4

      Install the nut to the clutch pedal support sub-assembly.

    2. A01IN5J

      Install the clutch pedal support sub-assembly with the 2 nuts and bolt.

      for bolt
      24 N*m 241 kgf*cm 17 ft.*lbf
      for nut
      18 N*m 178 kgf*cm 13 ft.*lbf

    3. Connect the clutch start switch assembly connector and clutch switch assembly connector.

  16. Click here

    INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN


    1. Apply MP grease to the contact surface of the clutch master cylinder push rod clevis with hole pin.

      Table 9. Text in Illustration
      *1 MP grease

    2. Connect the clevis to the clutch pedal sub-assembly with the clutch master cylinder push rod clevis with hole pin.

      Tip:

      Install the clutch master cylinder push rod clevis with hole pin from the right side of the vehicle.

    3. Install a new clip to the clutch master cylinder push rod clevis with hole pin.

  17. Click here

    INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY


    1. Inspect and adjust the clutch pedal sub-assembly (Click here).

  18. Click here

    INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY


    1. Install the lower No. 1 instrument panel airbag assembly (Click here).

  19. Click here

    INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY


    1. Install the instrument panel safety pad sub-assembly (Click here).