On-Vehicle Inspection

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
1. Pull back the floor carpet.
2. Check that the pedal height is correct.
  Pedal height from dash panel: 133.0 to 143.0 mm (5.236 to 5.630 in.)
3. If the pedal height is not as specified, adjust it as follows.
  1. Loosen the lock nut and turn the stopper bolt until the correct height is obtained.
  2. Tighten the lock nut.
    Torque: 16 N.m (160 kgf*cm, 12 ft.*lbf)
    
    Fig 1: Identifying Pedal Height
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT AND ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY
1. Check that the pedal free play and push rod play are correct.
  1. Depress the pedal until clutch resistance begins to be felt.
    Pedal free play: 5.0 to 15.0 mm (0.197 to 0.591 in.)
  2. Gently depress the pedal until the resistance begins to increase a little.
    Push rod play at pedal top: 1.0 to 5.0 mm (0.039 to 0.197 in.)
    
    Fig 2: Identifying Pedal Free Play
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Adjust the pedal free play and push rod play.
  1. Loosen the lock nut and turn the push rod until the correct free play and push rod play are obtained.
  2. Tighten the lock nut.
    Torque: 12 N.m (120 kgf*cm, 8.7 ft.*lbf)
  3. After adjusting the pedal free play, check the pedal height.
INSPECT AND ADJUST CLUTCH RELEASE POINT
1. Check the clutch release point.
  1. Pull the parking brake lever and install a wheel stoppers.
  2. Start the engine and run it at idle.
  3. Without depressing the clutch pedal, slowly move the shift lever into reverse until the gears come into contact.
  4. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.
    
    Fig 3: Identifying Clutch Release Point
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard distance:
    
    25 mm (0.98 in.) or more (From pedal stroke end position to release point)
    
    If the distance is not as specified, perform the following operations.
    - Check pedal height.
    - Check push rod play and pedal free play.
    - Bleed the clutch line.
    - Check the clutch cover assembly and disc assembly.