CLUTCH PEDAL (for 1KD-FTV) INSTALLATION


  1. INSTALL CLUTCH PEDAL SPRING HOLDER


    1. A01BAJRE01

      Apply MP grease to the inside of a new clutch pedal spring holder.

    2. Install the clutch pedal spring holder.

  2. INSTALL CLUTCH PEDAL PAD


    1. Install the clutch pedal pad to the clutch pedal sub-assembly.

  3. INSTALL CLUTCH PEDAL NO. 1 CUSHION


    1. A01BFV4

      Using needle-nose pliers, install the clutch pedal No. 1 cushion to the clutch pedal sub-assembly.

  4. INSTALL CLUTCH PEDAL SHAFT COLLAR


    1. A01BECGE06

      Apply MP grease to the inner, outer and end surfaces of 2 new pedal bushes.

    2. Install the clutch pedal shaft collar and 2 pedal bushes to the clutch pedal sub-assembly.

  5. INSTALL CLUTCH PEDAL SUB-ASSEMBLY


    1. A01BBP8E01

      Align the matchmarks on the clutch pedal support sub-assembly.

    2. Install the clutch pedal sub-assembly to the clutch pedal support sub-assembly with the bolt, washer and nut.

      Torque:
      34 N*m  { 350 kgf*cm, 25 ft.*lbf }

      Tech Tips

      Hold the nut and tighten the bolt.

  6. INSTALL TURNOVER SPRING SEAT COMPRESSION SPRING


    1. A01BB4ME02

      Apply MP grease to the sliding portion of the turnover spring seat compression spring.

    2. Install the turnover spring seat compression spring.

  7. INSTALL CLUTCH PEDAL SPRING


    1. A01BCZOE02

      Apply MP grease to the sliding portion of the clutch pedal spring.

    2. A01BHUCE02

      Install the clutch pedal spring.

      Note

      Be sure to install the clutch pedal spring with its end facing upward.

    3. Install a new E-ring.

  8. INSTALL CLUTCH SWITCH ASSEMBLY


    1. Using a 14 mm union nut wrench, install the clutch switch assembly.

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    2. Connect the clutch switch connector.

  9. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY


    1. A01BAM3E01

      Align the clip of the clutch pedal support with the hole of the bracket on the vehicle, and install the clutch pedal support sub-assembly.

      Note

      Make sure that the clip of the clutch pedal support is securely engaged in the hole of the bracket on the vehicle.

    2. A01BD7F

      Install the clutch pedal support sub-assembly with the bolt.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    3. A01BEKME01

      Apply MP grease to the sliding portions of the push rod clevis and clutch pedal sub-assembly.

    4. Install the push rod clevis to the cutout of the clutch pedal sub-assembly from the right side of the vehicle and push it downward.

      Note

      Check that the push rod cannot be turned 30° or more in order to confirm that the clevis is securely engaged to the clutch pedal sub-assembly.

    5. Connect the clutch switch connector and attach the wire harness clamp.

  10. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY


    1. A01BHS1

      Install the clutch master cylinder with the 2 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

  11. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT

    Click here

  12. INSTALL NO. 1 AIR DUCT

  13. INSTALL WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY (for LHD)


    1. Install the windshield washer motor and pump with the 2 bolts.

      Torque:
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

  14. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL


    1. A01BB5ME01

      Engage the 8 claws and install the instrument panel finish panel lower center.

  15. INSTALL SHIFTING HOLE COVER ASSEMBLY


    1. A01BF5BE01

      Manual Transmission:

      Engage the 6 claws and install the shifting hole cover assembly.

    2. Automatic Transmission:

      Engage the 8 claws and install the sifting hole cover assembly.

  16. INSTALL SHIFT LEVER KNOB

  17. INSTALL PARKING BRAKE HOLE COVER


    1. A01BF1ME01

      Engage the 6 claws and install the parking brake hole cover.

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


    1. A01BE86E01

      Engage the 3 claws.

    2. Install the instrument panel No.1 under cover sub-assembly with the 2 clips.

  19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL


    1. A01BHMVE01

      Engage the 4 clips (B).

    2. Install the instrument panel finish panel lower with the 2 clips (A).

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 47 in.*lbf }

  21. PERFORM INITIALIZATION

    Some systems need initialization when disconnecting the cable from the negative battery terminal. Click here