CLUTCH PEDAL(for RHD) INSTALLATION

PROCEDURE

  1. INSTALL CLUTCH PEDAL TURNOVER BUSH

    U122779

    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
      V100135

      MP grease

  2. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING

    C207427

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

      Table 2. Text in Illustration
      V100135

      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. INSTALL NO. 1 CLUTCH PEDAL CUSHION

    1. C207421

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

  4. INSTALL CLUTCH PEDAL BUSHING

    U123181

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

      Table 3. Text in Illustration
      V100135

      MP grease

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

  5. INSTALL CLUTCH PEDAL PAD

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

  6. INSTALL CLUTCH PEDAL SUB-ASSEMBLY

    1. C207419

      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 left side of the vehicle.

  7. INSTALL PEDAL SPRING HOOK (for Diesel)

    U123185

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

      Table 4. Text in Illustration
      V100135

      MP grease

    2. Install the pedal spring hook.

  8. INSTALL PEDAL WITH HOOK SPRING (for Diesel)

    U123183

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

      Table 5. Text in Illustration
      V100136

      MP grease

    2. Install the hook spring.

  9. INSTALL CLUTCH PEDAL STOPPER BOLT

    1. C207418

      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.

  10. INSTALL CLUTCH PEDAL SPRING HOLDER

    U122777

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

      Table 6. Text in Illustration
      V100135

      MP grease

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

  11. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING

    U123188

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

      Table 7. Text in Illustration
      V100135

      MP grease

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

  12. INSTALL CENTER OVER SPRING CAP

    C205130

    1. Install the center over spring cap to the clutch pedal sub-assembly.

      Tip:

      Install the center over spring cap from the right side of the vehicle.

  13. INSTALL CLUTCH START SWITCH ASSEMBLY

    C202172

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

      16 N*m

      160 kgf*cm

      12 ft.*lbf

  14. INSTALL CLUTCH SWITCH ASSEMBLY

    Click here

  15. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY

    1. C207416

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

      for bolt

      19 N*m

      195 kgf*cm

      14 ft.*lbf

      for nut

      18 N*m

      178 kgf*cm

      13 ft.*lbf

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

  16. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN

    C363513E01

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

      Table 8. Text in Illustration

      *A

      for Gasoline

      *B

      for Diesel
      V100135

      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 left side of the vehicle.

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

  17. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

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

  18. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

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

  19. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

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