CLUTCH RELEASE CABLE INSTALLATION


  1. INSTALL CLUTCH RELEASE CABLE ASSEMBLY


    1. A0137Q6E01

      Apply lithium soap base glycol grease to the clevis of the clutch pedal.

    2. Install the clutch release cable onto the clevis of the clutch pedal.

    3. A01391YE02

      Apply lithium soap base glycol grease to the clevis of the clutch release lever.

    4. Install the clutch release cable onto the manual transaxle.

    5. A0138CPE02

      While holding the clutch release lever, turn the cable end clamp and secure it to the flat area of the clutch release lever.

    6. Move your hand away from the clutch release lever and turn the cylinder portion of the cable end clamp and push it into the groove of the clutch release lever.

    7. LHD:

      A01368LE01

      1. Engage the clutch release cable with the 3 brackets (A) and install the grommet (B) into the piercing hole.

    8. A01371VE01

      RHD:


      1. Engage the clutch release cable with the bracket (A) and install the grommet (B) into the piercing hole.

    9. Depress the clutch pedal a few times to ensure the clutch release cable works smoothly.

      Note

      Depress the clutch pedal 50 times or more when replacing the clutch release cable with a new one.

    10. A0138CPE03

      Gently push the clutch release lever down by hand and make sure that it stops at the position shown in the illustration.

  2. INSTALL CLUTCH RELEASE FORK RETURN TENSION SPRING

    A0138ACE01

    1. Install the clutch release fork return tension spring onto the release fork retracting spring hanger.

  3. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY


    1. Turn up the floor carpet.

    2. A0137UAE01

      Check whether the pedal height is correct.

      Pedal height from floor panel
      LHD
      135 to 145 mm (5.31 to 5.71 in.)
      RHD
      161 to 171 mm (6.34 to 6.74 in.)

    3. Adjust the pedal height.


      1. Loosen the lock nut and turn the stopper bolt until the height is correct.

      2. Tighten the lock nut.

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }
    4. A013903E01

      Check that the pedal free play is correct.


      1. Depress the pedal until the resistance begins to be felt.

        Pedal free play
        13 to 23 mm (0.512 to 0.906 in.)
    5. A01391EE01

      Adjust the pedal free play.


      1. Turn the clutch release cable adjusting nut until the pedal free play is correct.

        Note

        Confirm that the clutch cable boot is installed.

      2. After adjusting the pedal free play, check the pedal height.

    6. Check the clutch release point.


      1. Pull the parking brake lever and install the wheel stopper.

      2. Start the engine and allow it to idle.

      3. A0137CGE01

        Without depressing the clutch pedal, slowly adjust the shift lever to the reverse position until the gears come into contact with the clutch pedal.

      4. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.

        Standard distance
        20 mm (0.787 in.) or more (from pedal stroke end position to release point)

        If the distance is not as specified, perform the following operations.


        • Check the pedal height.

        • Check the pedal free play.

        • Check the clutch cover and disc.

        • Check the pedal stroke.

        Pedal stroke
        148 mm (5.83 in.)

  4. INSTALL COWL PANEL SUB-ASSEMBLY

    A01377P

    1. Install the cowl top panel with the 10 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }
    2. A01390L

      Install the grommet of the wire harness.

    3. Install the clamp of the wire harness.

  5. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY


    1. Connect the connector.

    2. A0136OQ

      Install the front wiper motor and link assembly with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  6. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. Connect the washer hose.

    2. A0136GYE01

      Engage the 8 claws and install the cowl top ventilator louver RH.

    3. Install the clip.

  7. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. Connect the washer hose.

    2. A0136Y2E01

      Engage the 9 claws and install the cowl top ventilator louver LH.

    3. Install the clip.

  8. INSTALL HOOD TO COWL TOP SEAL

    A01379NE01

    1. Engage the 8 clips and install the hood to cowl top seal.

  9. INSTALL FRONT WIPER ARM LH

    A01390ME03

    1. Scrape any metal powder off the serrated part of the wiper arm with a round file or equivalent (when reinstalling).

    2. Clean the wiper pivot serrations with a wire brush.

    3. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    4. Provisionally install the front wiper main arm with the nut.

    5. Install the front wiper secondary arm onto the front wiper motor and link assembly.

    6. A0138WNE04

      Align the blade tip with the mark on the windshield glass, as shown in the illustration.

    7. Tighten the nut of the front wiper main arm.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  10. INSTALL FRONT WIPER ARM HEAD CAP

    A0137M4

    1. Engage the claw and install the front wiper arm head cap.

  11. INSTALL BATTERY HOLD DOWN CLAMP

    A0135TUE03

    1. Install the battery clamp with the 3 bolts.

      Torque:
      Bolt A
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
      Bolt B
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Engage the 2 wire harness clamps.

  12. INSTALL ENGINE ROOM RELAY BLOCK

    A0138XKE01

    1. Engage the claw and install the relay block.

    2. Install the 2 bolts.

      Torque:
      Bolt A
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Bolt B
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  13. INSTALL BATTERY

    A0136YXE02

    1. Install the battery onto the battery clamp, as shown in the illustration.

      Note


      • The identification line should be seen after installing the battery.

      • The battery clamp should be in contact with the battery after the installation.

    2. A0136EQE01

      Install the battery clamp with the bolt.

      Torque:
      15 N*m  { 154 kgf*cm, 11 ft.*lbf }

    3. Connect the battery positive terminal with the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  14. INSTALL INSTRUMENT PANEL ASSEMBLY


    1. Engage the 4 clips and 5 claws and install the instrument panel assembly.

      Note

      Make sure that there are no gaps between the instrument panel upper and instrument panel lower panel.

      A0138IQ

    2. Install the bolt <A>, 2 nuts <D> and 2 screws <B>.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf, for bolt <A> }
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf, for nut <D> }
      A0137GXE01
    3. A0138UJ

      Connect the airbag connector, as shown in the illustration.

    4. A0136KRE02

      Engage the 2 claws and close the cover.

  15. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY

    A0136KWE01

    1. Connect the connectors.

    2. Engage the 4 clips and 3 claws and install the instrument cluster finish panel center.

    3. Install the screw <B>.

    4. Install the control knob.

  16. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    A0136BT

    1. Connect the connector.

    2. A01362K

      Install the 2 screws.

  17. INSTALL INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY NO. 2

    A0136QKE01

    1. Engage the 2 claws.

  18. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

  19. INSTALL INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY

  20. INSTALL FRONT PILLAR GARNISH RH

    A0138GXE01

    1. Remove the adhesive tape and protective cover.

    2. A0138EWE01

      Install a new clip.

    3. Engage the 2 claws and 2 clips, and install the front pillar garnish.

  21. INSTALL FRONT PILLAR GARNISH LH

  22. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH

    A01380D

    1. Install the front door opening trim weatherstrip.

  23. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH

  24. INSTALL TACHOMETER (w/ TACHOMETER)

    A0135U6

    1. Install the tachometer with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    2. Connect the connector.

  25. INSTALL STEERING COLUMN COVER UPPER

    A0136TV

    1. Install the steering column cover upper, as shown in the illustration (w/ tachometer).

    2. A0136OJE02

      While turning the steering wheel to the right and left, engage the 4 claws and install the steering column cover upper with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
    3. A0137VI

      Tighten the screw behind the tachometer (w/ tachometer).

      Note

      Tighten the screw if the tachometer has been extended and the column cover has been removed.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  27. INSPECT SRS WARNING LIGHT