Repair Procedures

Removal

1. Disconnect the two ignition lock switch connectors.
2. Remove the clutch pedal mounting nuts(A-2ea) and the bracket mounting nut.




3. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).




4. Remove the screws or nut mounting the master cylinder to the clutch pedal assembly.

Installation

1. Apply the specified grease to the clutch pedal and bushings.

Chassis grease: SAE J310a, NLGI No.1




2. Install the screws or nut mounting the master cylinder to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and washer.

Wheel bearing grease: SAE J310, NLGI No.2

4. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B).




5. Install the clutch pedal mounting nuts (A-2ea).

Tightening torque :
17 - 26Nm (1.7 - 2.6kgf.m, 12.3 - 18.8Ib-ft)




6. Adjust the clutch pedal within the standard value, then secure by tightening the lock nut.

Standard value
Free play (A)
6 - 13mm (0.24 - 0.51 in)
Height (B)
182.8mm (7.19 in)





Inspection

1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.

Ignition lock switch inspection
Remove the ignition lock switch and check for continuity between the terminals. If the continuity is not as specified, replace the switch.





Standard value
Full stroke(A) : 12.0 ± 0.3mm (0.472 ± 0.012 in.)
ON-OFF point (B) : 2.0 ± 0.3mm (0.078 ± 0.012 in)