CLUTCH PEDAL(for LHD) ADJUSTMENT

PROCEDURE

  1. INSPECT AND ADJUST CLUTCH PEDAL

    1. Check that the clutch pedal stroke is correct.

      1. While raising the clutch pedal by hand so that it contacts the clutch pedal stopper bolt, confirm that the clutch pedal stroke is within the specified range.

        Clutch Pedal Stroke

        144.0 to 164.0 mm (5.67 to 6.45 in.)

      2. C308760C01

        *a

        Clutch Pedal Stroke

        If the clutch pedal stroke is not within the specified range, loosen the clutch pedal stopper nut and turn the clutch pedal stopper bolt until the correct clutch pedal stroke is obtained.

      3. Tighten the clutch pedal stopper nut.

        15.7 N*m

        160 kgf*cm

        12 ft.*lbf

    2. Check that the clutch pedal height is correct.

      1. Turn back the floor carpet.

      2. C303612C01

        *a

        Clutch Pedal Stopper Nut

        *b

        Clutch Pedal Stopper Bolt

        *c

        Clutch Pedal Height

        While raising the clutch pedal by hand so that it contacts the clutch pedal stopper bolt, confirm that the clutch pedal height is within the specified range.

        Clutch Pedal Height from Floor

        154.3 to 168.3 mm (6.05 to 6.62 in.)

      3. If the clutch pedal height is not within the specified range, loosen the clutch pedal stopper nut and turn the clutch pedal stopper bolt until the correct height is obtained.

      4. Tighten the clutch pedal stopper nut.

        15.7 N*m

        160 kgf*cm

        12 ft.*lbf

      5. Install the floor carpet to the original position.

    3. Adjust clutch release cable assembly.

      1. Set the clutch release cable end clamp and adjust nut of the clutch release cable assembly to their initial positions.

        C308756C01

        *a

        3.0 mm (0.118 in.)

        *b

        5.0 mm (0.197 in.)

        *c

        31.0 mm (1.22 in.)

        -

        -
      2. C308758

        Raise the clutch pedal and support it with an object so that remains in contact with the clutch pedal stopper bolt.

        Note:

        Make sure that the clutch release cable assembly does not come off of the clutch pedal while it is raised.

      3. C308757C01

        *1

        Clutch Release Fork Lever

        *a

        Push

        *b

        Turn

        Pull up the clutch release fork lever by hand and tighten the clutch release cable end clamp until it contacts the flat portion of the clutch release fork lever.

        Tip:

        If the clutch release cable end clamp cannot be tightened to contact the flat portion of the clutch release fork lever, loosen the adjust nut and adjust the length of the clutch release cable assembly.

      4. C308759

        Engage the clutch release cable end clamp to the groove of the clutch release fork lever.

        Note:

        • Make sure that the clutch release cable end clamp is properly engaged to the groove of the clutch release fork lever.

        • If the clutch release cable end clamp is not properly engaged to the groove of the clutch release fork lever, rotate the clutch release cable end clamp clockwise 90° to engage it properly.

      5. C308839C01

        *a

        Wear Reserve Stroke

        Tighten or loosen the adjust nut so that the wear reserve stroke is within the specified range.

        Wear Reserve Stroke

        28.0 to 48.0 mm (1.10 to 1.89 in.)

        Tip:

        • The wear reserve stroke increases when the adjust nut is loosened.

        • Do not tighten the adjust nut if it is in the initial position. (The adjust nut can be loosened.)

  2. INSPECT CLUTCH RELEASE POINT

    CAUTION:

    When checking the clutch release point, ensure that the vehicle is secure.

    1. C156453C02

      *a

      20 mm (0.787 in.)

      *b

      Release Point

      *c

      Clutch Pedal Stroke

      *d

      Full Stroke End Position

      Check the clutch release point.

      1. Be sure to apply the parking brake and secure the wheels using wheel chocks.

      2. Start the engine and run it at idle.

      3. Without depressing the clutch pedal, slowly move the shift lever to R until the gears contact.

      4. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.

        Standard Distance

        20 mm (0.787 in.) or more (from pedal stroke end position to release point)

        If the distance is not as specified, perform the following procedures:

        • Check the clutch pedal height.

        • Check the clutch cover assembly and clutch disc assembly.

        • Check the clutch pedal stroke.