Diesel Data: Automotive Repair

Installation








CLUTCH: CLUTCH PEDAL: INSTALLATION

INSTALLATION





1. INSTALL CLUTCH PEDAL NO.1 CUSHION
(a) Install the clutch pedal No. 1 cushion onto the clutch pedal.





2. INSTALL CLUTCH PEDAL BUSH
(a) Apply MP grease to the 2 bushes and collar.
(b) Install the 2 bushes and collar onto the clutch pedal.
3. INSTALL CLUTCH PEDAL PAD





4. INSTALL CLUTCH PEDAL SUB-ASSEMBLY
(a) Install the clutch pedal onto the clutch pedal support with the bolt and the nut.
Torque: 37 Nm (375 kgf-cm, 27 ft-lbf)
HINT: Install the bolt from the right side of the vehicle.

5. INSTALL CLUTCH PEDAL SPRING





6. INSTALL CLUTCH PEDAL STOPPER BOLT
(a) Install the clutch pedal stopper bolt so that its end touches the clutch pedal cushion.
HINT: Tighten the lock nut to the specified torque when adjusting the clutch pedal.





7. INSTALL CLUTCH START SWITCH ASSEMBLY
(a) Install the clutch start switch with the nut.
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)





8. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
(a) Install the clutch pedal support onto the vehicle with the bolt.
Torque: 24 Nm (241 kgf-cm, 17 ft-lbf)
(b) Connect the clutch start switch connector.
(c) Connect the wire harness clamp.
9. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY Installation
10. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE Installation
11. INSTALL CLUTCH RESERVOIR TUBE Installation
12. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER (for Hatchback)
Installation
13. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER (for Sedan)
Installation
14. INSTALL BRAKE BOOSTER ASSEMBLY
Installation
15. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY Testing and Inspection
16. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1 Installation