Removal and installation the clutch pedal (Opel Astra G)

Wiring diagram for connecting the master cylinder pushrod to the clutch pedal

Removal

1. In the vehicle interior, remove the lower trim section from the left side of the instrument panel (see Chapter Body).

2. Disconnect the return spring from the clutch pedal. Remove the retainer and remove the pin attached to the pedal of the split pin of the push rod of the clutch master cylinder (see illustration Wiring diagram for connecting the master cylinder pushrod to the clutch pedal).

3. Remove the two bolts securing the pedal support bracket to the steering crossmember.

4. On models equipped with a speed control system (tempostat), disconnect the electrical wiring and remove the pedal position sensor switch from the bracket (see illustration Wiring diagram for connecting the master cylinder pushrod to the clutch pedal).

5. Remove the two nuts securing the pedal bracket to the engine compartment bulkhead/clutch master cylinder.



6. Push the master cylinder studs back so they do not stick out of the bulkhead.

7. Carefully remove the pedal assembly and take it out of the passenger compartment.

8. Check the pedal bracket for deformation and damage (the unit is made easily deformable to improve safety in the event of a collision). Assess the degree of wear of the bushings. Replace the failed components. If necessary, the pedal can be removed from the bracket by unscrewing the mounting bolts.

Installation

1. If the pedal assembly has been disassembled, reinstall all removed components - the pedal axle and bushings should be lubricated with a multi-purpose grease before installation. Connect the return spring and tighten the fasteners securely. Before installing the assembly on the car, check the smoothness of the pedal movement.

2. Install the pedal assembly on the engine compartment bulkhead - make sure that the split pin of the master cylinder pusher is seated correctly. Tighten the bolts securing the assembly to the steering crossmember.

3. Using the push rod, push the master cylinder mounting studs through the bulkhead and into the holes in the pedal assembly bracket. Install new mounting nuts and tighten them to the specified torque.

4. Lubricate the axial pin of the split pusher pin with universal grease, place it on the clutch pedal and secure it with the mounting pin - make sure the retainer is securely seated.

5. Tighten the pedal-to-steering crossmember bolts to the required torque.

6. Connect the return spring.



7. On models equipped with a cruise control, install the clutch pedal position sensor switch, having first pressed its nipple in. Connect the electrical wiring to the sensor, then press the clutch pedal all the way down, pull out the sensor plunger and release the pedal again to allow the sensor to self-install.

8. Reinstall the lower instrument panel trim section. Before operating the vehicle, make sure the clutch is functioning properly.