CLUTCH PEDAL (for 1KD-FTV) INSTALLATION


  1. INSTALL CLUTCH PEDAL SPRING HOLDER


    1. A003EZ0E03

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

      Text in Illustration
      A003DCD MP grease

    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. A003EBG

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

  4. INSTALL CLUTCH PEDAL SHAFT COLLAR


    1. A003DPRE07
      Text in Illustration
      *1 Pedal bush
      *2 Clutch pedal shaft collar
      A003DCD MP grease

      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. A003HFLE04
      Text in Illustration
      *a Matchmarks

      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 TURN OVER SPRING SEAT COMPRESSION SPRING


    1. A003DA5E03

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

      Text in Illustration
      A003DCD MP grease

    2. Install the turnover spring seat compression spring.

  7. INSTALL CLUTCH PEDAL SPRING


    1. A003DLBE03
      Text in Illustration
      *a Spring end
      A003DCD MP grease

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

    2. A003AZNE04
      Text in Illustration
      *A for LHD
      *B for RHD

      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. A003HGVE01

      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. A003DJA

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

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    3. A003DHKE02

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

      Text in Illustration
      A003DCD MP grease

    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. A003CFD

      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. w/ Rear Wiper:

      Connect the 2 connectors and 2 washer hoses.

    2. w/o Rear Wiper:

      Connect the connector and washer hose.

    3. Attach the hose clamp.

    4. Install the windshield washer motor and pump assembly with the 2 bolts.

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

    5. Connect the connector to the windshield washer motor and pump assembly.

  14. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL


    1. Attach the 8 claws to install the instrument panel finish panel lower center.

  15. INSTALL SHIFTING HOLE COVER ASSEMBLY


    1. for Manual Transmission:

      Attach the 6 claws to install the shifting hole cover assembly.

    2. for Automatic Transmission:

      Attach the 8 claws to install the shifting hole cover assembly.

  16. INSTALL SHIFT LEVER KNOB

  17. INSTALL PARKING BRAKE HOLE COVER


    1. Attach the 6 claws to install the parking brake hole cover.

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


    1. Attach the 3 claws to instrument panel under cover sub-assembly No. 1.

    2. Install the the 2 clips.

  19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL


    1. Connect the fuel lid lock control cable and bonnet (hood) control cable assembly to the instrument panel finish lower.

    2. Attach the 4 clips to install the instrument panel finish panel lower.

    3. Install the 2 clips.

  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