Clutch Pedal Assembly: Service and Repair
REMOVAL1. ACCELERATOR PEDAL
1. Disconnect ground cable from battery.
2. Disconnect accelerator cable from throttle body.
CAUTION: Be careful not to kink accelerator cable.
3. Remove instrument panel lower cover from instrument panel, and connector.
4. Disconnect accelerator cable from accelerator pedal lever.
5. Working inside engine compartment, remove casing cap out of the toe board by turning it clock-wise.
6. Pull out the cable from the toe board hole.
7. Remove accelerator pedal connecting bolt from accelerator pedal bracket.
2. BRAKE AND CLUTCH PEDAL
1. Disconnect ground cable from battery.
2. Remove instrument panel lower cover from instrument panel.
3. Disconnect the following parts from pedal bracket.
^ Operating rod of brake booster
^ Electrical connectors (for stop light switch, etc.)
4. Remove clevis pin which secures lever to push rod.
5. Remove nut which secures clutch master cylinder.
6. Remove bolts and nuts which secure brake and clutch pedals, and remove pedal assembly.
3. BRAKE PEDAL
1. Disconnect ground cable from battery.
2. Remove instrument panel lower cover from instrument panel.
3. Remove clevis pin which secures brake pedal to brake booster operating rod. Also disconnect stop light switch connector.
4. Remove the two bolts and the four nuts which secure brake pedal to pedal.
INSPECTION
1. BRAKE AND CLUTCH PEDALS
1 of 2
2 of 2
Move brake and clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kg, 2 lb.) to ensure pedal deflection is in specified range.
Deflection of brake and clutch pedal: Service limit 5.0 mm (0.197 inch) or less
CAUTION: If excessive deflection is noted, replace bushings with new ones.
2. ACCELERATOR PEDAL
Lightly move pedal pad in lateral the direction to ensure pedal deflection is in specified range.
Deflection of accelerator pedal: Service limit 5.0 mm (0.197 inch) or less
CAUTION: If excessive deflection is noted, replace bushing and clip with new ones.
3. STOP LIGHT SWITCH
If stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one.
Specified position: L 2.8 +1.5/0 mm (0.110 +0.059/0 inch)
ASSEMBLY
1. BRAKE AND CLUTCH PEDAL
1. Attach stop light switch, etc. to pedal bracket temporarily.
2. Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores.
3. Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring and clutch pedal effort reducing spring (vehicle with hill holder), and then install pedal bolt.
Tightening torque: T2: 29 ±7 Nm (3.0 ±0.7 kg.m, 21.7 ±5.1 ft. lbs.)
NOTE: Clean up inside of bushings and apply grease before installing spacer.
4. Set brake pedal position by adjusting position of stop light switch.
Pedal position: L 125.9 mm (4.96 inch)
Tightening torque: T1: 8 ±2 Nm (0.8 ±0.2 kg-m, 5.8 ±1.4 ft. lbs.)
2. ACCELERATOR PEDAL
Clean and apply grease to spacer and inside bore of accelerator pedal. Install accelerator pedal onto pedal bracket.
INSTALLATION
1. Install in the reverse order of removal.
CAUTION:
^ Be careful not to bend clutch cable too much.
^ Never fail to cover outer cable end with boot.
^ Be careful not to kink accelerator cable.
^ Make sure that holder and casing cap are securely connected.
2. Adjust clutch pedal.
3. Adjustment after pedal installation, refer to Clutch Pedal Assembly; Adjustments.
Adjustments