REMOVAL AND INSTALLATION



caution Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch. In addition, do not use gloves which have grease on them.
Pre-removal OperationClutch Fluid Draining
Post-installation Operation
  • Clutch Fluid Supplying
  • Clutch Bleeding (Refer to ).






Removal steps


·
Reservoir hose and brake fluid reservoir connection (Refer to ). <RH drive vehicles>


·
Brake master cylinder assembly and brake booster (Refer to GROUP 35A, Master cylinder assembly and brake booster ). <LH drive vehicles>
<<A>>
>>C<<
1.
Clutch hose <LH drive vehicles>, clutch pipe assembly <RH drive vehicles> and clutch master cylinder connection


·
Front pillar trim <LH> (Refer to GROUP 52A, Interior Trim <COLT> or <COLT-CZ3>). <LH drive vehicles>


·
Side cover <LH> and under cover <LH drive vehicles> or Under cover <RH drive vehicles> (Refer to GROUP 52A, Instrument panel ).


·
Hood lock release handle (Refer to GROUP 42, Hood ). <LH drive vehicles>
<<B>>

·
Junction block <LH drive vehicles>


2.
Reservoir hose


3.
Clutch master cylinder clip


4.
Clutch master cylinder pin


5.
Nut


6.
Clutch master cylinder


7.
Harness connector connection <Vehicles with 4G1 engine, AS&G system or cruise control system>

>>B<<
8.
Clutch switch <Vehicles with 4G1 engine or cruise control system> or clutch switch (A) <Vehicles with AS&G system>


9.
Harness connector connection <Vehicles with AS&G system>

>>A<<
10.
Clutch switch (B) <Vehicles with AS&G system>


11.
Stopper


12.
Nut


13.
Clutch pedal assembly


14.
Pedal pad


15.
Bushing

REMOVAL SERVICE POINTS



<<A>> CLUTCH HOSE <LH DRIVE VEHICLES>, CLUTCH PIPE ASSEMBLY <RH DRIVE VEHICLES> AND CLUTCH MASTER CYLINDER DISCONNECTION



Use a screwdriver to push out the clip, and disconnect the clutch hose or clutch pipe assembly from the clutch master cylinder.

<<B>> JUNCTION BLOCK <LH DRIVE VEHICLES> REMOVAL



Remove the junction block by loosening the mounting screws.

INSTALLATION SERVICE POINTS



>>A<< CLUTCH SWITCH (B) <VEHICLES WITH AS&G SYSTEM> INSTALLATION



1.
caution Pulling out the plunger section too frequently may damage the automatic adjustment mechanism section of the clutch switch (B) because it is made of plastics. If the plunger section is pulled out at least 2 or 3 times, replace the clutch switch (B).
Pull out the plunger section of the clutch switch (B) to the maximum length (approximately 26 mm).
note The clutch switch (B) incorporates the automatic adjustment mechanism for the plunger section.

2.
caution Install the clutch switch (B) (connector colour: grey) to the position as shown.
Fully depress and hold the clutch pedal. Push in the clutch switch (B) to the clutch pedal assembly bracket, and turn it clockwise in order to install.
note By installing the clutch switch (B) as described above, the plunger section is adjusted to the standard value automatically.
3.Connect the connector (connector colour: grey) of the clutch switch (B).

>>B<< CLUTCH SWITCH <VEHICLES WITH 4G1 ENGINE OR CRUISE CONTROL SYSTEM> OR CLUTCH SWITCH (A) <VEHICLES WITH AS&G SYSTEM> INSTALLATION



1.
caution Pulling out the plunger section too frequently may damage the automatic adjustment mechanism section of the clutch switch or clutch switch (A) because it is made of plastics. If the plunger section is pulled out at least 2 or 3 times, replace the clutch switch or clutch switch (A).
Pull out the plunger section of the clutch switch or clutch switch (A) to the maximum length (approximately 26 mm).
note The clutch switch or clutch switch (A) incorporates the automatic adjustment mechanism for the plunger section.

2.
caution Install the clutch switch or clutch switch (A) (connector colour: blue) to the position as shown.
Hold the clutch pedal to prevent it from moving, and press in the clutch switch or clutch switch (A) to the bracket of the clutch pedal assembly. Then, turn the clutch switch or clutch switch (A) clockwise to install it.
note By installing the clutch switch or clutch switch (A) as described above, the plunger section is adjusted to the standard value automatically.
3.Connect the clutch switch or clutch switch (A) connector (connector colour: blue).

>>C<< CLUTCH HOSE <LH DRIVE VEHICLES>, CLUTCH PIPE ASSEMBLY <RH DRIVE VEHICLES> AND CLUTCH MASTER CYLINDER CONNECTION



Reset the clip in the original position and connect the clutch hose or clutch pipe assembly to the clutch master cylinder.