Toyota Yaris: Clutch Stroke Sensor / Installation

Toyota Yaris XP210 (2020-2023) Reapir and Service Manual / Drivetrain / Clutch / Clutch Stroke Sensor / Installation

INSTALLATION

PROCEDURE

1. INSTALL CLUTCH PEDAL STROKE SENSOR ASSEMBLY

(a) When installing a new clutch pedal stroke sensor assembly:

NOTICE:

Do not break the clutch pedal stroke sensor assembly lever set pin before being instructed to do so.

(1) Install a new clutch pedal stroke sensor assembly to the clutch pedal support assembly with the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

NOTICE:

  • Engage the clutch pedal stroke sensor assembly lever with the clutch pedal groove.
  • Check that there is no foreign matter attached to the contact surface of the clutch pedal stroke sensor assembly.
  • Check that the tip of the clutch pedal stroke sensor assembly lever is protruding from the clutch pedal groove.
  • Do not drop the clutch pedal stroke sensor assembly.
  • If the clutch pedal stroke sensor assembly has been dropped, replace the clutch pedal stroke sensor assembly with a new one.
  • Do not subject the clutch pedal stroke sensor assembly to shock during installation.
  • Make sure to confirm that the clutch pedal fully returns to its original position.

*a

Clutch Pedal Stroke Sensor Assembly Lever

*b

Clutch Pedal Groove

*c

Clutch Pedal Stroke Sensor Assembly Lever Set Pin

(2) Connect the clutch pedal stroke sensor assembly connector.

(3) Firmly depress the clutch pedal sub-assembly to break the clutch pedal stroke sensor assembly lever set pin.

(4) Remove the broken clutch pedal stroke sensor assembly lever set pin.

(b) When reusing the clutch pedal stroke sensor assembly:

(1) Install the clutch pedal stroke sensor assembly to the clutch pedal support assembly and temporarily tighten the 2 nuts.

NOTICE:

  • Engage the clutch pedal stroke sensor assembly lever with the clutch pedal groove.
  • Check that there is no foreign matter attached to the contact surface of the clutch pedal stroke sensor assembly.
  • Check that the tip of the clutch pedal stroke sensor assembly lever is protruding from the clutch pedal groove.
  • Do not drop the clutch pedal stroke sensor assembly.
  • If the clutch pedal stroke sensor assembly has been dropped, replace the clutch pedal stroke sensor assembly with a new one.
  • Do not subject the clutch pedal stroke sensor assembly to shock during installation.
  • Make sure to confirm that the clutch pedal fully returns to its original position.

HINT:

When fully tightening the nuts, perform Adjust Clutch Pedal Stroke Sensor Assembly first.

*a

Clutch Pedal Stroke Sensor Assembly Lever

*b

Clutch Pedal Groove

(2) Connect the clutch pedal stroke sensor assembly connector.

2. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

3. ADJUST CLUTCH PEDAL STROKE SENSOR ASSEMBLY

NOTICE:

When the clutch pedal stroke sensor assembly is being reused, perform the following procedure to adjust it.

(a) Connect the GTS to the DLC3 with the ignition switch off.

(b) Turn the ignition switch to ON.

(c) Turn the GTS on.

(d) Enter the following menus: Powertrain / Engine / Data List / Clutch Stroke Sensor Voltage.

Powertrain > Engine > Data List

Tester Display

Clutch Stroke Sensor Voltage

(e) Read the stroke sensor value in the Data List, and turn the clutch pedal stroke sensor assembly slowly to the right or left to adjust the output voltage so that it is within the following range.

Standard Voltage (clutch pedal fully released):

0.96 to 1.04 V

(f) Tighten the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

NOTICE:

After turning the ignition switch to ON, do not depress the clutch pedal sub-assembly until the nuts have been tightened.

(g) Turn the GTS off and turn the ignition switch off.

(h) Disconnect the GTS from the DLC3.

4. INSTALL BRAKE PEDAL RETURN SPRING

Click here

5. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

6. CHECK AND CLEAR DTC

Click here

    Removal

    REMOVAL PROCEDURE 1. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Click here 2. REMOVE BRAKE PEDAL RETURN SPRING Click here 3. REMOVE CLUTCH PEDAL STROKE SENSOR ASSEMBLY (a) Disconnect the clutch pedal stroke sensor assembly connector...

    Clutch System

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    Break-In Period

    No special break-in is necessary, but a few precautions in the first 600 miles (1,000 km) may add to the performance, economy, and life of the vehicle.

    Do not race the engine. Do not maintain one constant speed, either slow or fast, for a long period of time. Do not drive constantly at full-throttle or high engine rpm for extended periods of time. Avoid unnecessary hard stops. Avoid full-throttle starts.

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