Subsequent Work

1. Fit fuse box and clip in the six connectors. -arrow- 
   Fig 1: Locating Fuse Box

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2. Fit left plenum panel partition, ensuring correct seating of gaskets and correct routing of wiring harness.
3. Fit cowl panel cover → WM 664419 REMOVING AND INSTALLING COWL PANEL COVER .
4. Install engine design cover → 700219 REMOVING AND INSTALLING FRONT COVER (ENGINE COMPARTMENT) .
5. Bleed the clutch → 300107 BLEEDING THE CLUTCH SYSTEM .
6. Connect the battery → Connecting And Disconnecting Battery .

   Information 

If clutch switches 22-23 on the mounting saddle for clutch pedal 21 have been removed, they must be replaced. Afterwards check operation of new clutch switches.

Check operation of both clutch switches -22-23-  (see below: first switch (clutch pedal switch), second switch (interlock).

Fig 2: Overview Of Pedals Excluding Stop Light Switch

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• 1 - Seal
• 2 - Hexagon nut
• 3 - Mounting saddle
• 4 - Pin
• 5 - Hexagon nut
• 6 - Hexagon-head bolt
• 7 - Seal
• 8 - Fixing clip/screw
• 9 - Master cylinder
• 10 - Mounting
• 11 - Bolt
• 12 - Clutch pedal
• 13 - Cap
• 14 - Lock (mechanical)
• 15 - Clutch power spring
• 16 - Bearing shell
• 17 - Rubber stop
• 18 - Lock (mechanical)
• 19 - Pin
• 20 - Lock (mechanical)
• 21 - Mounting saddle for clutch pedal
• 22 - Switch (clutch pedal switch)
• 23 - Switch (interlock)

1. First switch (clutch pedal switch) -22- 

   Connect System Tester and select >> PSM <<system. In the menu >> Input signals/clutch switches <<read out the switch states.

   From end-position 1 of the clutch pedal (pedal not depressed!) to a pedal travel of 11 mm -A-  the switch (clutch pedal switch) must be at >> Not actuated <<in the System Tester. Measured using a steel rule at the tread plate of the clutch pedal - second worker required.

   Fig 3: Depressing Clutch Pedal (Rest Position)

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   Depress clutch pedal over (!) 11 mm pedal travel:

   • Now the switch (clutch switch) must switch to >> Actuated <<.

   If the switch (clutch pedal switch) does not operate, the installation position must be checked. If that does not succeed, then follow the troubleshooting procedure in the instructional procedures>> Group 0, Diagnostic Repair Group 40-66, PSM Fault Code 650 <<.

2. Second switch (interlock) -23- 

   Connect System Tester and select >> Kessy <<system. In the menu >> Input signals/clutch switches (interlock) <<read out the switch states.

   From end-position 2 of the clutch pedal (pedal fully depressed!) minus 20 mm -B-  the switch (interlock) must be at >> Actuated <<in the System Tester. Measured using a steel rule at the tread plate of the clutch pedal - second worker required.

   Fig 4: Pressing Clutch Pedal End-Position

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   Depress clutch pedal up to 20 mm before (!) end-position2:

   • Up to that point the switch (interlock) must be at >> Not actuated <<in the System Tester.

   If the switch (interlock) does not switch over, the installation position must be checked. If that does not succeed, then follow the troubleshooting procedure in the instructional procedures >> Group 0, Diagnostic Repair Group 91-97, Kessy Fault Code 650 <<.