Clutch Pedal: Installation

WARNING: This page is about a different variant/trim than selected.

INSTALL CLUTCH PEDAL SWITCH ASSEMBLY
1. Install the clutch pedal switch assembly to the clutch pedal support sub-assembly with the nut.
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
INSTALL CLUTCH SWITCH ASSEMBLY (w/ Cruise Control System)
1. Install the clutch switch assembly to the clutch pedal support sub-assembly with the nut.
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING
1. Apply MP grease to the inside of a new clevis bushing.
2. Install the clevis bushing to the clutch pedal sub-assembly.
  HINT:
  
  Install the clevis bushing from the right side of the vehicle.
  
  Fig 1: Locating Grease Applying Area On Clevis Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 CLUTCH PEDAL CUSHION
1. Install the 2 No. 1 clutch pedal cushions to the clutch pedal sub-assembly and clutch pedal support sub-assembly.
  
  Fig 2: Locating Clutch Pedal Sub-Assembly Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH PEDAL BUSHING
1. Apply MP grease to both sides and end surface of 2 new bushings.
2. Install the 2 bushings to the clutch pedal.
INSTALL CLUTCH PEDAL PAD
1. Install the clutch pedal pad to the clutch pedal sub-assembly.
  
  Fig 3: Locating Grease Applying Area On Clevis Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH PEDAL SUB-ASSEMBLY
1. Install the clutch pedal sub-assembly to the clutch pedal support sub-assembly with the bolt and nut.
  Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf)
  
  HINT:
  
  Install the bolt from the right side of the vehicle.
  
  Fig 4: Locating Clutch Pedal Sub-Assembly Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING
1. Apply MP grease to the sliding portion of the 2 turn over bushings.
2. Install a 2 new turn over bushings to the clutch pedal sub-assembly and clutch pedal support sub-assembly.
3. Install the turn over spring.
  
  Fig 5: Locating Grease Applying Area On Turn Over Bushings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH PEDAL SPRING (for 2AZ-FE)
1. Install the clutch pedal spring.
  
  Fig 6: Identifying Clutch Pedal Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH PEDAL STOPPER BOLT
1. 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.
  
  Fig 7: Locating Clutch Pedal Stopper Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
1. Install the nut to the clutch pedal support sub-assembly.
  
  Fig 8: Identifying Clutch Pedal Support Sub-Assembly Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clutch pedal support sub-assembly with the 2 nuts and bolt.
  Torque: Bolt
  
  24 N*m (241 kgf*cm, 17 ft.*lbf)
  
  Nut
  
  13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  Fig 9: Locating Clutch Pedal Support Sub-Assembly Bolt And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN
1. Connect the clevis to the clutch pedal sub-assembly with the hole pin.
  HINT:
  
  Install the hole pin from the right side of the vehicle.
2. Install the clip to the hole pin.
CONNECT CONNECTORS
1. Connect the clutch pedal switch connector.
2. Connect the clutch switch assembly connector.
Fig 10: Identifying Clip And Hole Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK)
1. Install the main body ECU with the 3 screws.
INSPECT CLUTCH PEDAL SWITCH ASSEMBLY (See ON-VEHICLE INSPECTION )
INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY
(See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSPECT SRS WARNING LIGHT
(See DIAGNOSIS SYSTEM )

Fig 11: Locating Main Body ECU Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002