Hyundai Tucson: Clutch System / Clutch Pedal Repair procedures

Inspection
Clutch Pedal Inspection
1.
Measure the clutch pedal height (from the face of the pedal pad to the floor board) and the clutch pedal clevis pin play (measured at the face of the pedal pad.)

Standard value
Stroke (A): 150 ± 3 mm (5.9055 ± 0.118 in.)
Free play (B): 6 ~ 13 mm (0.2362 ~ 0.5118 in.)
Height (C): 167 mm (6.5748 in.)

Ignition Lock Switch Inspection
1.
Disconnect 2P-connector from a ignition lock switch.
2.
Disconnect the ignition lock switch.
(if you can install a tester with the switch fixed, this step can be omissible)
3.
Check for continuity between terminals.
(refer to the table below)
   
If there is difference between what tested and the table above, replace the ignition lock switch with a new one.
Pedal position
Clutch switch
Ignition lock 
switch
Released 
Pressed
(Continuity)
Released (Open)
Fully pressed 
Released (Open)
Pressed 
(Continuity)


Standard value
Full stroke (A): 12.0 ± 0.3mm (0.4724 ± 0.0118 in.)
ON-OFF point (B): 2.0 ± 0.3mm (0.0787 ± 0.0118 in)

Removal
   
Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off immediately with water.
1.
Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
2.
Disconnect the clutch tube (B) and reservoir hose (A) from the clutch master cylinder.

3.
Remove the crash pad lower panel.
(Refer to "Interior(Crash pad)" in BD group).
4.
Disconnect the ignition lock switch connector (B) and clutch switch (A).
5.
Remove the clutch pedal assembly mounting nut (C-3ea) and bolts (D-1ea).

Tightening torque:
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 Ib-ft)

6.
Remove the clutch pedal and the master cylinder assembly together.
Installation
1.
Installation is in reverse order of removal.
   
Perform bleeding air procedure in clutch release cylinder after pouring the brake fluid.
(Refer to "clutch release cylinder" in CH group.)
Clutch Pedal Components and Components Location
Components 1. Reverse hose2. Master cylinder3. Siller4. Member assembly5. Turn over spring6. Clutch switch7. Clutch arm8. Pedal pad9. Ignition lock switch10. Stopper ...

Clutch Master Cylinder Components and Components Location
Components 1. Reverse hose2. Master cylinder3. Siller4. Member assembly5. Turn over spring6. Clutch switch7. Clutch arm8. Pedal pad9. Ignition lock switch10. Stopper ...

Other information:

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