CLUTCH RELEASE CABLE(for 1KR-FE) INSTALLATION

PROCEDURE

1. INSTALL CLUTCH RELEASE CABLE ASSEMBLY (for LHD)

   1. Install the clutch cable bracket to the vehicle body with 2 nuts.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

   2. Install the 2 clamp brackets to the vehicle body with the bolt and nut.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

   3. 

      Lithium soap base glycol grease

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

   4. Connect the clutch release cable assembly to the clevis of the clutch pedal sub-assembly.

   5. 

      Connect the clutch release cable assembly to the manual transaxle assembly.

   6. 

      Lithium soap base glycol grease

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

   7. 

      *1	Clutch Release Fork Lever
      *a	Push
      *b	Turn

      While pushing the clutch release fork lever, adjust the clutch release cable end clamp.

   8. Slowly release the clutch release fork lever and ensure that the clutch release cable end clamp is correctly located in the groove of the clutch release fork lever.

   9. Engage the clutch release cable assembly to the 2 clamp brackets, clutch cable bracket and install the clutch release cable grommet to the hole in the vehicle body.

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

       Note:

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

2. INSTALL CLUTCH RELEASE CABLE ASSEMBLY (for RHD)

   1. Install the clutch cable bracket to the vehicle body with the 2 nuts.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

   2. 

      Lithium soap base glycol grease

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

   3. Connect the clutch release cable assembly to the clevis of the clutch pedal sub-assembly.

   4. 

      Lithium soap base glycol grease

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

   5. Connect the clutch release cable assembly to the manual transaxle assembly.

   6. 

      *1	Clutch Release Fork Lever
      *a	Push
      *b	Turn

      While pushing the clutch release fork lever, adjust the cable end clamp.

   7. Slowly release the clutch release fork lever and ensure that the clutch release cable end clamp is correctly located in the groove of the clutch release fork lever.

   8. Engage the clutch release cable assembly to the clutch cable bracket and install the clutch release cable bracket to the hole in the vehicle body.

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

      Note:

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

3. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (for LHD)

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4. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (for RHD)

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5. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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6. INSTALL BATTERY

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7. INSTALL OUTER COWL TOP PANEL (for LHD)

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8. INSTALL OUTER COWL TOP PANEL (for RHD)

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9. INSTALL FRONT AIR SHUTTER SEAL RH (for LHD)

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10. INSTALL FRONT AIR SHUTTER SEAL RH (for RHD)

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11. INSTALL FRONT NO. 1 VENTILATOR SEAL (for LHD)

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12. INSTALL FRONT NO. 1 VENTILATOR SEAL (for RHD)

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13. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

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14. INSTALL UPPER INSTRUMENT PANEL ASSEMBLY

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15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When reconnecting the cable, some systems need to be initialized after the cable is reconnected.

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