Remove the instrument cluster unit.
Remove the top of the instrument panel.
Remove the clutch master cylinder push rod fork with the pin. Remove the clamp and pull the pin out of the hole.
Remove the clutch pedal.
Fig. 3.6. Clutch pedal components: 1 – nut; 2 – Clutch pedal switch connector; 3 – clutch pedal switch; 4 – clutch pedal mounting nuts; 5 – retainer; 6 – fork axle; 7 – fork bushing; 8 – fork stem mounting nut; 9 – fork stem; 10 – fork; 11 – pedal pad; 12 – clutch pedal
Disconnect the clutch switch connector. Unscrew the three nuts, remove the clutch pedal assembly with the bracket.
Fig. 3.7. Removing the compression spring
Remove the servo compression spring. To do this, use a small screwdriver to remove the E-ring, then remove the compression spring (Fig. 3.7).
Install the clutch master cylinder pushrod bushing. Apply grease to the inside of the new bushing. Install the pushrod bushing into the clutch pedal hole.
Install the first clutch pedal buffer.
Install the clutch pedal cover.
Install the spring cover.
Install the clutch pedal servo bushing. Apply grease to the inside of the new bushing before installation.
Fig. 3.8. Installing the clutch pedal bushings
Apply grease to both surfaces of two new clutch pedal bushings and install them into the pedal hole (Fig. 3.8).
Install the clutch pedal assembly into the clutch pedal bracket and secure with the bolt and nut.
Tightening torque: 36.8 Nm.
Fig. 3.9. Installing the compression spring
Apply grease to the contact surfaces of the bushing and compression spring. Using needle-nose pliers, install the E-ring and put the servo seat compression spring in place (Fig. 3.9).
Install the clutch pedal assembly and secure with three nuts.
Tightening torque: 18.6–22.5 Nm
Connect the clutch switch connector.
Apply grease to the contact surfaces of the pin and the bore of the clutch master cylinder pushrod fork bushing. Connect the fork to the clutch pedal with a pin. Install the clamp on the pin.
Install the top of the instrument panel.
Install the instrument cluster unit.
Install the instrument cluster trim panel.
Check and adjust the clutch pedal.