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How do change my clutch cable?
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Anyone who has had a 19 for any length of time will probably have had the cable snap on them so many time they can do them in their sleep, its an easy job, but a bit fiddly, especially if you have big fingers!
I have used this method on 1.4E and 16v engines, but should pretty much be the same for all types.
You will need:
Penknife with a coarse saw blade.
New cable.
Some string.
Adjustable spanner.
1) Put kettle on. Make coffee.
2) Check cable is pre-greased, if its not, then apply some all-purpose grease down the length of it, by applying some to the exposed inner cable at both ends and working it through. If you skip this step, then the cable will seize and strip the pedal ratchet.
3) Unhook cable from clutch end in the engine bay.
4) Pull broken inner cable out.
5) Remove lower exhaust heatshield. (16v only)
6) The plastic grommet in the footwell is a swine to get out. Use the hacksaw blade to saw the end off it. It will then drop out.
7) Take outer cable out of engine bay. Note how it is routed, there should be clips to hold it in place.
8) Put a foot or so of string through the hole in the footwell.
9) Working in engine bay, tie the end of the cable to the string, and get the cable roughly in place. Don't attach either end yet though.
10) Loop string once through the steering wheel (This is so the end of the cable is being pulled in roughly the correct direction from the footwell, and then run it out of the car. Pull the string with one hand and use the other to guide the pedal end of the cable through hole in the footwell.
11) Working in the footwell, pull the pedal end of the cable until the grommet is roughly lined up with the hole. Pull the string. It might 'pop' in, it might not.
12) Attach pedal end of cable. (Make sure it goes through the loop on top of the pedal)
13) Attach the clutch end of the cable.
14) We are now in a state where the cable is in, but the grommet is not seated correctly yet. By connecting the ends, we have put 'tension' on the cable.
15) Get the grommet lined up. Look in the footwell to see how to correct the angle, go to the bay and give it a wiggle, to try and seat it. Do this until it is lined up well.
16) Once grommet is lined up. Press the pedal a couple of times to pop it in. If it doesn't pop, repeat 15-16 again until it does.
17) Drink coffee, check cable is in the clips in the bay for it and put the exhaust manifold shield back on.
18) Check the gears all go in. You are done now.