5.1 Clutch Pedal Drive Cable Location on Later Models (with clutch cable adjustment)
2. The clutch pedal on these models is installed after installing a new cable or if the pedal clearance has increased due to clutch wear. The clutch pedal clearance on earlier models (designation starting with "J11") is adjusted automatically.
3. The mechanism works as follows: spring 3 (see illustration) acts on the traction on toothed segment 2. The clutch pedal drive cable is always under tension, i.e. the release bearing is constantly in contact with the clutch diaphragm spring.
5.3 Self-adjusting clutch, numerical designations are given in the text
4. When the clutch pedal is pressed, protrusion 1 hits the toothed segment and prevents rotation so that the cable is tensioned again.
5. If the clutch or clutch pedal drive cable was removed, press the pedal several times after installation to make adjustments.
6. Installation of such a cable design cannot be called easy, so use help. Perform the following work only if there is no other way out. Otherwise, contact a car repair shop.
7. Disconnect the clutch pedal drive cable from the clutch release fork in the engine compartment (see illustration 2.3 in Section 7).
8. Remove the luggage rack 1 in the passenger compartment (see illustration). Two screws (2 and 3) secure the trim panel. Also remove screws 4 and the hood drive cable (5). Remove the steering column cover.
5.8 Remove the parts to gain access to the cable mount on the pedal; numerical designations are given in the text
9. Press the clutch pedal and pull the cable.
10. Hold the cable on the ledge with 1 hand (see illustration 5.3) and release the clutch pedal. The end of the cable will then be released from the toothed segment (2) and can be pulled out.
11. Pass the cable through the hole in the body (use a screwdriver) and remove it completely from the engine compartment.
12. Pass the new cable from the engine compartment into the vehicle interior, pull it through protrusion 1 and toothed segment 2, as shown in Illustration 5.3.
13. Connect the other end of the cable to the clutch release fork (see illustration 2.3 in Section 7).
14. Press the clutch pedal to feed the cable through the hole in the floor of the car. Make sure that the cable enters the hole exactly.
15. Press the pedal several times to allow automatic adjustment. Correct operation is checked by moving the clutch release lever. The free play should be 17-18 mm on the "X" section (see illustration). If so, the self-adjusting system will work perfectly, but check the system again. To do this, start the engine, press the clutch pedal and engage reverse. Noise in the gearbox indicates poor disengagement.
5.15 Check the operation of the automatic clearance adjustment after connecting the clutch pedal drive cable - the lever should move within the distance "X" (17-18 mm).
16. Removing and installing the clutch pedal drive cable without an automatic regulator is much easier. Perform the work in accordance with Illustration 5.1.
17. Open the hood and locate the end of the clutch pedal drive cable on the clutch release lever. Loosen both nuts (see illustration), to disconnect the cable from the lever.
5.17 Fastening the clutch pedal drive cable to the clutch release lever; nuts 1 and 2 are designed to adjust the pedal clearance; the gap is measured on the section indicated by the arrows
18. In the passenger compartment, remove the steering column switch trim (5 screws) under the steering wheel. Depending on the model, you may also have to loosen the radio screw. Disconnect the instrument panel light switch from the terminal.
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19. Remove the switch trim on the steering column above the steering wheel. Disconnect the end of the cable from the clutch pedal and pull the cable out. When doing this, pay attention to how the rubber cable guides are positioned so that you can install them correctly later.
20. Install in reverse order. After installing the cable, adjust its clearance. The free play is 3 -.4 mm on the section indicated by the arrows (see illustration 5.17).
21. To check the clutch pedal adjustment, have an assistant hold it down and pull the pedal drive cable until you feel a noticeable resistance. Use both nuts to adjust the free play and finally lock the nuts against each other.