Removal
1. Working inside the car, release the retaining clips (turn them 90°), then remove the hidden dashboard panel located on the driver's side. Remove the retainer (press the central pin with a screwdriver, then pull out the outer part of the retainer) and remove the heating/ventilation system duct to gain easier access to the pedal.
2. Pull out the retaining clip and remove the pushrod fork pin securing the master cylinder pushrod to the pedal.
3. Where necessary, disconnect the electrical connector from the clutch pedal switch.
4. Loosen and remove the master cylinder mounting nuts and separate the cylinder push rod from the pedal.
5. Fully depress the clutch pedal, then loosen and remove the upper pedal bracket mounting bolt and remove the pedal assembly from under the lower portion of the instrument panel.
6. If necessary, clamp the pedal bracket in a vice and remove the assembly as follows.
7. On 4-cylinder models, unhook the return spring, noting its orientation. Remove the pivot bolt nut retaining bracket, then loosen and remove the nut and washer. Remove the pivot bolt and separate the pedal and return spring from the mounting bracket.
8. On 6-cylinder models, carefully unhook the lower end of the return spring from the pedal and remove the spring assembly, noting the correct locations of the ends. Remove the pivot bolt nut retaining bracket, then loosen and remove the nut and washer. Remove the pivot bolt and separate the pedal from the mounting bracket, noting the location of the thrust washer.
9. On all models, check the pedal components for damage. If any component is worn or damaged, replace it. Installation
10. If the pedal and bracket assembly has been removed, apply a small amount of multi-purpose grease to the pedal pivot bolt and bushings before reassembling.
11. On 4-cylinder models, install the return spring to the pedal, then install the assembly into the mounting bracket. Insert the pivot bolt, then install the washer and nut, and tighten the nut to the specified torque Specifications. Attach the pivot bolt nut with a bracket, then hook the return spring into the working position.
12. On 6-cylinder models, install the pedal into the bracket, then make sure the thrust washer has not moved and insert the pivot bolt. Install the washer and nut onto the pivot bolt, then tighten the nut to the specified torque Specifications and attach it with a bracket. Make sure the tips are positioned on the return spring as noted during removal, then install the assembly onto the pedal and bracket with the smaller tip facing the pedal.
13. On all models, place the pedal and bracket assembly in the operating position and install the upper mounting bolt. Align the master cylinder push rod with the pedal, then install the master cylinder mounting nuts. Tighten the master cylinder nuts and pedal bracket bolt to the specified torque Specifications.
14. Apply a little multipurpose grease to the fork pushrod pin, then align the fork and pedal and insert the pin. Secure the pin with a clip (it should fit into the groove of the pin).
[Material copied from this website: www.OPELBOOK.ru]
15. Connect the wiring connector to the clutch pedal switch (where necessary), then install the lower instrument panel cover and the heating/ventilation duct.
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