Clutch Pedal Assembly: Service and Repair

REPLACEMENT
1. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER
2. REMOVE CLUTCH PEDAL SPRING (W/O TURN OVER)





3. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
a. Remove the clip and hole pin.





4. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSY
a. w/ Cruise control: Disconnect the clutch switch assy connector.
b. Disconnect the clutch start switch assy connector.
c. Remove the 2 nuts, bolt and clutch pedal support assy.





5. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING (W/ TURN OVER)
a. Mount the clutch pedal in a soft jaw vise.
b. Using a screwdriver, remove the spring.
6. REMOVE CLUTCH PEDAL TURNOVER BUSH (W/ TURN OVER)





7. REMOVE CLUTCH PEDAL SUB-ASSY
a. Remove the bolt and nut.
b. Remove the clutch pedal sub-assy from the clutch pedal support.
8. REMOVE CLUTCH PEDAL PAD





9. REMOVE CLUTCH PEDAL BUSH
a. Remove the 2 bushes from the clutch pedal.





10. REMOVE CLUTCH PEDAL No. 1 CUSHION
a. Using needle-nose pliers, remove the No. 1 cushion from the clutch pedal.





11. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
a. Using a 8 mm hexagon wrench and a hammer, remove the clevis bush from the clutch pedal sub-assy.





12. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
a. Apply MP grease to inside of a new clevis bush.
b. Install the clevis bush to the clutch pedal.

HINT: Install the clevis bush from the right side of the vehicle.





13. INSTALL CLUTCH PEDAL No. 1 CUSHION
a. Using needle-nose pliers, install the No. 1 cushion to the clutch pedal.





14. INSTALL CLUTCH PEDAL BUSH
a. Apply MP grease to both side of 2 new bushes.
b. Install the 2 bushes to the clutch pedal.
15. INSTALL CLUTCH PEDAL PAD





16. INSTALL CLUTCH PEDAL SUB-ASSY
a. Install the clutch pedal sub-assy to the clutch pedal support with the bolt and nut.
Torque: 36.8 Nm (375 kgf-cm, 27 ft. lbs.)

HINT: Install the bolt from the right side of the vehicle.





17. INSTALL CLUTCH PEDAL TURNOVER BUSH (W/ TURN OVER)
a. Apply MP grease to inside of the turn over bush.
b. Install the turn over bush to the clutch pedal sub-assy.
18. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING (W/ TURN OVER)
a. Apply MP grease to the contact surface of the bush and spring.
b. Install the spring to the clutch pedal sub-assy and clutch pedal support.





19. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSY
a. Install the clutch pedal support to the vehicle with the 2 nuts and bolt.
Torque:
Bolt: 19.1 Nm (195 kgf-cm, 14 ft. lbs.)
Nut: 11.8 Nm (120 kgf-cm, 9 ft. lbs.)
b. Connect the clutch start switch assy connector.
c. w/ Cruise control: Connect the clutch switch assy connector.





20. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
a. Apply MP grease to the contact surface of the hole pin and clevis bush.
b. Connect the clevis to the clutch pedal sub-assy with the hole pin.

HINT: Install the hole pin from the right side of the vehicle.

c. Install the clip to the hole pin.
21. INSTALL CLUTCH PEDAL SPRING (W/O TURN OVER)
22. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER
23. INSPECT SRS WARNING LIGHT
24. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSY