PEDAL SYSTEM AND CONTROL CABLES SUBARU. M_ MECHANISM AND FUNCTION 1, Pedal Effort Reducing Mechanism 2. Hydraulic Clutch Pedal System [TUI 1992 $ SPECIFICATIONS AND SERVICE DATA... (© COMPONENT PARTS 1, Pedal (Manual Transmission) 2. Pedal (Automatic Transmission) W SERVICE PROCEDURE SERVICE Dieinen canis MANUAL =| 2:Sitegometer catia T TROUBLESHOOTING4-6 IM1A0] PEDAL SYSTEM AND CONTROL CABLES 45 imag) PEDAL SYSTEM AND CONTRO M_ MECHANISM AND FUNCTION 41. Pedal Effort Reducing Mecha- nism mechanism uses a mechani- shown below. It is installed on ge force for the clutch pedal. et vehicles which require ‘A: CONSTRUCTION ‘An atm is made integral with the clutch pedal, and spring-hook is connected to thé arm end bushing. B: OPERATION When the clutch pedal is depressed, point A moves toward point B, spring-hook makes a swing. The pedal depressing effort becomes small when the prolonged line of the spring-hook passes over the center of the pedal shaft. BA107 Fig. 1PEDAL SYSTEM AND CONTROL CABLES [otB0)_ 4-5 ) 2. Hydraulic Clutch Pedal System [TURBO] A: CONSTRUCTION The hydraulic clutch pedal is connected to the master cylinder (which produces oil pressure) via a rod. ‘utch rarervor tank Clutch master eylinder Fulerurn Hydraulic cutek pedal Bests Fig. 2 B: OPERATION The operating principle of the hydraulic clutch pedal system is similar to that of a mechanical clutch pedal system except that a return spring returns the olutch pedal to the original position.4-5 _[S0A0] PEDAL SYSTEM AND CONTROL CABLES S SPECIFICATIONS AND SERVICE DATA A: SERVICE DATA ~ Yi —3 mom (0.04 — 0.12 10) Broke pedal Free play [Depress brake pedal ped with a force of less then AON (1 kg, 2 Bl) [Nor-Turbo: 10 — 20 mm (0.39 — 0.79 in) cltch pode fee Atchtch pedal pad Turbo: 3 — 16 mm (0.12 — 0.69 in) Full stoke [At clutch pedal pad 145 — 160 mm (6.71 — 6.91 Free) 0 = 4 mom (0.04 — student aac ploy [At pedal ped a (6.04 — 0.16 in) Stroke [At pedal pad) [46 — 60 mm (1.61 — 1.97 in) 4PEDAL SYSTEM AND CONTROL CABLES {c101) 4-5 ’ © COMPONENT PARTS 1. Pedal (Manual Transmission) 4. Non-TURBO Tightening torque: Nem (kg-m, ft-lb) Th: 13 — 23 (1.3 — 23, fee Ta: 18 — 23 (13 — 1 Pedal bracket 2. Brake pedal 3 Cltoh pedal 9 Stop lamp even 10 Brake pedal spring 11. Spring assist, 12 Bushing assist 13. Clutch cable 14 Gulch cable came 18. Stopper 16. Aconorator podal pa 17 Spring pin 48 Accolerator spring 48 Accelerator spring 20 21 lewis pin 22 Snap pin 22 Accelerator stopper 24 Olutch bracket 25 Clutch switch 84-15534-5 {C102} PEDAL SYSTEM AND CONTROL CABLES 2. TURBO Tightening torque: Nem (kg-m, FB) TH: 18 — 23 (13 — 28, 9 — 17) 32: 13 — 28 (1.3 — 23,9 — 17) 73: 23 — 96 (23 — 37, 17 — 27) Ta: 6 — 10 (0.6 — 1.0, 43 — 7.2) 6: 5A — 03 (0.55 — 0.95, 4.0 — 6.9) Peel bracket teh master cylinder Push rod Stopper ‘Accelerator pedal pad ‘Spring Accelerator spring Accelerater spring Helder reve pin Snap pin ‘Agcelerater stopper (luton breckot Fig. 4PEDAL SYSTEM AND CONTROL CABLES (C200) _4-5 2. Pedal (Automatic Transmission) Tightening torque: Nem (kg-m, Th: 18— 13-23 (1.3-2.3,9-17) 23-36 (23~3.7, 17-27) Ta: 6 ~ 100.6 - 1.0, 4.37.2) 5 20-~ 33 (2.0- 3.4, 14-25) 20. Aceslerator stopper 21 Pog 22 Kiek-down switch Ba1017 Fig. 5 (WAT model)4-1 iat} W SERVICE PROCEDURE 1. Pedal ‘A: ON-CAR SERVICE 4. BRAKE PEDAL 41) Check position of pedal pad. Ifit is not in specified value, adjust it by adjusting brake booster operating rod length. 2) Check free play by operating pedal by hand. If itis not in specified value, adjust it by adjusting posi- tion of stop lamp switch, Be careful not to rotete stop lamp switch. 3) Apply grease to operating rod connecting pin to pre- vent it from wearing. Free piey Stroke Pedal height ‘168 rm (8.22 in) 1 Stop ight switch 2 Mat 3. Toe board Brake’ pedal free play: 1.=3 mm (0.04 — 0.12 in) [Depress brake pedal pad with a force of fess than 10.8 (1 kg, 21b)] Ba-110| Fig. 6 PEDAL SYSTEM AND CONTROL CABLES 2, CLUTCH PEDAL 1) Check clutch pedal free play by operating pedal by hand. Foot ret Free play: Non-Turbo: at clutch pedal pad 10 — 20 mm (0.39 — 0.79 In) at center of cable on clutch release fork 3 — 4 mm (0.12 — 0.16 in) Turbo: at clutch pedal pad 3 — 15 mm ( 0.59 in) __S errr e4tsi7 Fig. 7 8PEDAL SYSTEM AND CONTROL CABLES IW1A2] 4-5. 3) Hydraulic application type [TURBO] (1) If It is out of specification, loosen lock nut for push rod and adjust push rod by turning in the direc- tion that shortens or lengthens it. Unit: nen (i) ook nut 1 Leek nut 2 Adjusting nut 3 alent fork Units mm (in) Ba-t12| Ful stroke Fig. & 148 (87) 2) Mechanical application type [Non-TURBO} (1) If itis not in specified value, adjust it by turning adjusting nut on engine side end of clutch cable. eo (2) Apply grease to connecting portion of clutch Fig. 9 pedal and clutch cable. Tightening torque (Adjusting nut) /9— 11 Nem (0.9 — 1.1 kg-m, 65 — 8.0 Fld) (2) Check the fluid level on the outside of the clutch master cylinder tank. If the level is below “MIN”, add clutch fluid to bring it up to "MAX", Racommended clutch fluid: FMVSS No. 116, fresh DOT 3 or DOT 4 brake fluid4-5 [W1A3} PEDAL SYSTEM AND CONTROL CABLES 3, ACCELERATOR PEDAL Check to ensure the kick down switch operates at the Check pedal stroke and free play by operating acceler- specified value in relation to the stroke of the accelera- ator pedal by hand. tor pedal. If itis not within specified value, adjust it by turning nut connecting accelerator cable to throttle body. 1 Stroke et cable end 2. Accalerator pedel 3 Stroke at pedal pod 4 Toeboord 8 Accelerator cable Free play at pedal pad: 0 —2 mm (0 — 0.08 in) 4 Accelerator pedal 2 Towbours 3 Accaleratorceble Baasr| Fig. 17 ‘stroke ot pedal pad 48 — 60 mm (181 — 1.97 i) Bet19) Fig. 10 10PEDAL SYSTEM AND CONTROL CABLES (wiB2) 4-5 B: REMOVAL 1. ACCELERATOR AND BRAKE PEDAL ASSY 1) Disconnect ground cable from battery. 2) Disconnect accelerator cable from throttle body. Too! 541176] Fig. 14 6} Disconnect accelerator and stop lamp switch har- ness connectors. ‘Tirotte leer | 7} Remove the pin which connects brake pedal and operating rod. 541174 Operating rod length is preset at the factory. Do not Fig. 12 attempt to loosen the lock nut. 3) Attach a wrench to the casing cap above tosboard, and tum the casing cap clockwise to remove it. 8) Remove nuts which secure pedal bracket. Fig. 13 2, CLUTCH PEDAL ASSY 4) Remove lower instrument cover located above : ‘accelerator and brake pedals. 1) Mechanical application type [Non-TURBO] 5) Remove bushing from front end of accelerator (1) Disconnect end of clutch cable on the engine pedal, side. While using a standard screwdriver or (2) Remove two flange nuts at bracket location, (3) Remove lower instrument cover. (4) Remove the bolt which secures bracket. (6) Remove clutch pedal ASSY together with clutch cable, 2) Hydraulic application type [TURBO] (1) Remove master cylinder cover. (2) Remove master cylinder mounting nuts, {8} Remove snap pin and clevis pin that join pushrod and clutch pedal. {4) Remove clutch pedal and bracket as a unit. "4. (W1C1] PEDAL SYSTEM AND CONTROL CABLES C: INSPECTION 1. ACCELERATOR AND BRAKE PEDAL ASSY 1) Disassemble accelerator and brake pedals. Remove grease from the shaft, spacer, and bushing and check these parts for wear or damay 2) Lightly move pedal ped in the ‘ensure pedal deflection is in specified range. Pee ee Deflection of accelerator pedal: Service limit 5.0 mm (0.197 in) or less. ee If oxcessive deflection is noted, replace bushing and clip with new ones. 2. CLUTCH PEDAL 41) Check pedal shaft and bushing for wear or damage. 2) Move brake and clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kg, 2 tb) to ensure pedal deflection is in specified range. ee Deflection of brake and clutch pedel: Service limit 5.0 mm (0.197 in) or less ——— If excessive deflection is noted, replace bushing and clip with new ones. 3. STOP LAMP SWITCH If stop lamp switch does not operate properly (or if it does not stop at the specified position), replece with a new one. 2 “1m (0.070 *9989in) oe | Fig. 16 4, KICK DOWN SWITCH If kick down switch does not operate properly (or if it does not stop at the specified position}, replace with a new one. LJ Bait78 Fig. 17 12