Installing Clutch Pedal

WARNING: Preloaded or pressurized components

Risk of squashing or bruising
→ Do not reach into the danger area.

→ Relieve the tension on components before starting work.

→ Secure components to prevent them from loosening suddenly.

NOTE: Aggressive fluids

Risk of damage to components and surfaces
→ Do not spill fluids.

→ In the event of contact, wash the component or surface with water.

→ Replace components that are already damaged.

Install clutch pedal -1- .

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Clutch pedal in mounting saddle (installation)
1. 1.1 Insert the clutch pedal -1- and clutch power spring assembly -2- into the mounting saddle -arrow A- .
2. 1.2 Press the clutch pedal -1- up until the bolts for the clutch power spring assembly -2- engage -arrow B- .
Information

The pedal shaft must not be greased during installation!
- The cover on the pedal shaft is coded. This means that the pedal shaft can only be fitted correctly in one specific position.
- When pushing in the pedal shaft -1- , make sure that the cut-out -2- on the pedal shaft fits into the guide -3- on the mounting saddle -4- .
- This is the only way to ensure that the brake pedal shaft is installed in the correct position and will not turn.
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Positioning pedal shaft
Install pedal shaft -2- .

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Pedal shaft in mounting saddle (installation)
1. 2.1 Align the clutch pedal with the pedal bearing axle and press the pedal shaft -2- through -arrow A- .
2. 2.2 Install retaining clip -1- for the pedal shaft -2- (-arrow B- ).
Secure the clutch master cylinder.

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Clutch master cylinder in mounting saddle (installation)
1. 3.1 Press in the clutch master cylinder -arrow A- and lock it by turning it clockwise -arrow B- .
2. 3.2 Press in retaining clip for push rod -1- on the clutch pedal -2- (-Arrow- ) until it locks with an audible click.
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Engaging push rod
Release clutch power spring assembly -2- .
1. 4.1 Press the clutch pedal -1- slightly -Arrow- until the cotter pin -3- can be pulled out of the clutch power spring axle.
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Securing clutch power spring assembly
Install mounting saddle.

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Fastening mounting saddle in the passenger compartment
1. 5.1 Tighten collar nuts -3- on mounting saddle inside the body.
  > Tightening torque 23 Nm (17 ftlb.)
2. 5.2 Tighten collar nuts -2- for brake booster on mounting saddle.
  > Tightening torque 23 Nm (17 ftlb.)
Install bearing pedestal screws from outside (plenum panel).
1. 6.1 Tighten screws -Arrows- above brake booster.
  > Tightening torque 23 Nm (17 ftlb.)
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Installing screws securing mounting saddle to the body from outside (as shown in figure)
Secure brake booster on the brake pedal. (Ball joint must engage fully in the fastening clip).
Pull stoppers off the supply and pressure lines.

Connect feed and pressure line.

9.1 Connect pressure line -1-arrow A- , until the locking mechanism engages securely.

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Hydraulic lines for clutch slave cylinder (installation)

9.2 Connect supply line -2- until it engages securely -arrow B- .

Connect electric plug connection -Arrow- ; the connector must engage securely.

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Electric plug connection to clutch master cylinder (installation)