CLUTCH PEDAL REMOVAL/INSTALLATION [D66M-R, D66MX-R]

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Caution

•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

•  Do not allow clutch fluid to get on a painted surface. Clutch fluid contains properties which can dissolve the paint. If clutch fluid gets on a painted surface, rinse with water immediately, then wipe the area dry.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the following parts as a single unit. (L.H.D.) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

3.  Remove the battery and battery tray. (L.H.D.) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the clutch pedal using the following procedure. (See Clutch Pedal Installation Note.)

(1)  Remove the bracket from the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

(2)  Disconnect the connectors and wiring harness clip shown in the figure from the clutch pedal and set the wiring harness aside.

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(3)  Remove the clutch pedal position switch. (See CLUTCH PEDAL POSITION SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(4)  Remove the starter interlock switch. (See STARTER INTERLOCK SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(5)  Remove the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

(6)  Disconnect the steering shaft from steering gear. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

(7)  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

(8)  Remove the insulator. (R.H.D.) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(9)  Disconnect the clutch stroke sensor connector.

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(10)  Disconnect the clutch pipe and hose No.1 from clutch master cylinder, and plug it to avoid clutch fluid leakage. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(11)  Disconnect the clutch reserve hose from clutch master cylinder, and plug it to avoid clutch fluid leakage. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(12)  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

6.  Fully depress the clutch pedal, and verify that the engine starts.

L.H.D.

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R.H.D.

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1	Nut
2	Clutch master cylinder (See CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION [D66M-R, D66MX-R].)
3	Clutch pedal
4	Pedal pad

Clutch Pedal Installation Note

1.  Install the clutch pedal installation nuts.

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2.  Connect the clutch reserve hose to clutch master cylinder. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

3.  Connect the clutch pipe and hose No.1 to clutch master cylinder. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

4.  Connect the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

5.  Install the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

6.  Bleed the air from the clutch system. (See CLUTCH FLUID REPLACEMENT/AIR BLEEDING [D66M-R, D66MX-R].)

7.  Inspect the clutch pedal. (See CLUTCH PEDAL INSPECTION [D66M-R, D66MX-R].)

8.  Install a new starter interlock switch. (See STARTER INTERLOCK SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

9.  Install a new clutch pedal position switch. (See CLUTCH PEDAL POSITION SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

10.  Connect the connectors, wiring harness clip and wiring harness shown in the figure to the clutch pedal.

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11.  Connect the clutch stroke sensor connector.

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12.  Install the insulator. (R.H.D.) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

13.  Install the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

14.  Install the bracket to the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)