Get CLUTCH Guide for Toyota Avensis 4 Door First Generation (1997-2003)

CLUTCH

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . .

CL–1

CL–3

CL–9

CLUTCH MASTER CYLINDER . . . . . . . . . . . .

CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFER TO AVENSIS/CORONA REPAIR MANUAL FOR

CHASSIS AND BODY (Pub. No. RM599E)

NOTE: The above pages contain only the points which differ

from the above listed manual.

CL–1

CLUTCH

–

CLUTCH PEDAL

Push Rod Play and

Freeplay Adjust Point

CL015–05

INSPECTION

1.

CHECK PEDAL HEIGHT

Pedal height from asphalt sheet:

LHD:

1ZZ–FE Engine:

139.7 – 149.7 mm (5.500 – 5.894 in.)

3ZZ–FE Engine:

139.7 – 149.7 mm (5.500 – 5.894 in.)

1AZ–FSE Engine:

Pedal Height

Adjust Point

Push Rod Play

148.3 – 158.3 mm (5.839 – 6.232 in.)

RHD:

1ZZ–FE Engine:

144.3 – 154.3 mm (5.681 – 6.075 in.)

3ZZ–FE Engine:

Pedal Height

144.3 – 154.3 mm (5.681 – 6.075 in.)

1AZ–FSE Engine:

152.9 – 162.9 mm (6.010 – 6.413 in.)

D02446

2.

IF NECESSARY, ADJUST PEDAL HEIGHT

Loosen the lock nut and turn the stopper bolt until the height is

correct. Tighten the lock nut.

3.

CHECK PEDAL FREEPLAY AND PUSH ROD PLAY

Depress pedal until clutch resistance begins to be felt.

Pedal freeplay:

1.0 – 5.0 mm (0.039 – 0.197 in.)

Gently push on the pedal until the resistance begins to increase

a little.

Push rod play at pedal top:

5.0 – 15.0 mm (0.197 – 0.591 in.)

4.

IF NECESSARY, ADJUST PEDAL FREEPLAY AND

PUSH ROD PLAY

(a) Remove the air duct and the lower finish panel

(See page BO–8).

(b) Loosen the lock nut and turn the push rod until the free-

play and push rod play are correct.

(c) Tighten the lock nut.

Pedal Freeplay

(d) After adjusting the pedal freeplay, check the pedal height.

(e) Connect the air duct and install the lower finish panel.

CL0102

AVENSIS/CORONA SUP (RM781E)

CL–2

CLUTCH

–

CLUTCH PEDAL

5.

CHECK CLUTCH RELEASE POINT

(a) Pull the parking brake lever and install wheel stopper.

(b) Start the engine and idle the engine.

(c) Without depressing the clutch pedal, slowly shift the shift

lever into reverse position until the gears make contact.

(d) Gradually depress the clutch pedal and measure the

stroke distance from the point the gear noise stops (re-

lease point) to the full stroke end position.

Standard distance:

25 mm (0.98 in) or more

Release

Point

Full Stroke

End Position

CL0512

25 mm (0.98 in.) or more

(From pedal stroke end position to release point)

If the distance is not as specified, perform the following opera-

tions.

S

Inspect pedal height.

Inspect push rod play and pedal freeplay.

Bleed the clutch line.

Inspect the clutch cover and disc.

AVENSIS/CORONA SUP (RM781E)

CL–3

CLUTCH

–

CLUTCH MASTER CYLINDER

CL016–03

COMPONENTS

LHD:

Lock Nut

Boot

Snap Ring

Clevis

Clip

Filler Cap

Reservoir Tank

Reservoir Hose

Push Rod

Piston

12 (120, 9)

Clip

Spring

Clip

1CD–FTV Engine LHD:

w/ Damper:

Inlet Union

O–Ring

Washer

Clutch Line

15(155, 11)

Master Cylinder

Body

Clevis

1ZZ–FE, 3ZZ–FE, 1AZ–FSE Engine RHD:

Filler Cap

Lock Nut

Float

Clevis

Snap Ring

Washer

Push Rod

Piston

Reservoir Tank

zGrommet

12 (120, 9)

Slotted Spring Pin

Spring

Clip

Boot

Clutch Line

15(155,11)

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

D02178

AVENSIS/CORONA SUP (RM781E)

CL–4

CLUTCH

–

CLUTCH MASTER CYLINDER

1CD–FTV Engine RHD:

Filler Cap

Float

Clevis

Clip

Reservoir Tank

Snap Ring

Push Rod

Piston

12 (120, 9)

zGrommet

Spring

Slotted Spring

Lock Nut

Boot

Washer

Clutch Line

15(155, 11)

Master Cylinder

Body

z Gasket

Clutch Accumulator

For use with SST: 32 (330, 24)

ForusewithoutSST:44(450,33)

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

D02437

AVENSIS/CORONA SUP (RM781E)

CL–5

CLUTCH

–

CLUTCH MASTER CYLINDER

CL017–07

REMOVAL

1.

DRAW OUT FLUID WITH SYRINGE

2.

LHD:

DISCONNECT RESERVOIR TANK

Disconnect reservoir tank from reservoir tank bracket.

D02438

3.

LHD:

DISCONNECT CLUTCH LINE

Using SST, disconnect the clutch line. Use a container to catch

the fluid.

SST

SST 09023–00100, 09249–63010

Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

4.

RHD:

DISCONNECT CLUTCH LINE

Using SST, disconnect the clutch line. Use a container to catch

the fluid.

RHD:

SST 09023–00100

Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

5.

6.

REMOVE CLIP AND PIN

REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-

TER CYLINDER AND GASKET

SST

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D02439

AVENSIS/CORONA SUP (RM781E)

CL–6

CLUTCH

–

CLUTCH MASTER CYLINDER

CL051–02

DISASSEMBLY

1.

LHD:

REMOVE RESERVOIR TANK

(a) Using a pliers, disconnect the 2 clips.

Yellow Mark

(b) Remove the reservoir tank from reservoir hose.

(c) Remove the reservoir hose from inlet union.

White Mark

D02444

D02445

D02440

D00277

D00279

(d) Remove the inlet union.

2.

RHD:

REMOVE RESERVOIR TANK

(a) Using a pin punch and hammer, drive out the slotted

spring pin.

(b) Remove the reservoir tank and grommet.

3.

REMOVE PUSH ROD

(a) Pull back the boot and remove the snap ring with snap

ring pliers.

(b) Pull out the push rod and washer.

(c) Remove the piston from the cylinder.

4.

1CD–FTV ENGINE RHD:

REMOVE CLUTCH ACCUMULATOR

Using SST, remove the accumulator and gasket.

SST 09922–10010

SST

AVENSIS/CORONA SUP (RM781E)

CL–7

CLUTCH

–

CLUTCH MASTER CYLINDER

CL052–03

REASSEMBLY

SST

1.

1CD–FTV ENGINE RHD:

INSTALL CLUTCH ACCUMULATOR

Using SST, install the accumulator with a new gasket.

SST 09922–10010

Torque:

For use with SST:

32 N·m (330 kgf·cm, 24 ft·lbf)

For use without SST

44 N·m (450 kgf·cm, 33 ft·lbf)

HINT:

Fulcrum

Length

D00280

Use a torque wrench with a fulcrum length of 345 mm (13.58

in.).

2.

COAT PARTS WITH LITHIUM SOAP BASE GLYCOL

GREASE, AS SHOWN IN ILLUSTRATION

INSERT PISTON INTO CYLINDER

INSTALL PUSH ROD ASSEMBLY WITH NEW GASKET

AND NEW PISTON STOP PLATE

3.

4.

CL0528

D02444

D02441

5.

LHD:

INSTALL RESERVOIR TANK

(a) Install the O–ring and inlet union.

(b) Facing the white mark upwards, install the reservoir hose

to the reservoir tank.

(c) Facing the yellow mark upwards, install the reservoir hose

to the cylinder.

Yellow Mark

White Mark

(d) Using a pliers, connect the 2 clips.

6.

RHD:

INSTALL RESERVOIR TANK

(a) Install the reservoir tank and a new grommet.

(b) Using a pin punch and hammer, drive in the slotted spring

pin.

Protrusion

1.5 – 3.5 mm

(0.059 – 0.138 in.)

AVENSIS/CORONA SUP (RM781E)

CL–8

CLUTCH

–

CLUTCH MASTER CYLINDER

CL01A–02

INSTALLATION

Installation is in the reverse order of removal (See page CL–5).

HINT:

After installation, bleed the clutch system and adjust the clutch pedal.

AVENSIS/CORONA SUP (RM781E)

CL–9

CLUTCH

–

CLUTCH UNIT

CL01J–04

COMPONENTS

19 (195, 14)

Release Bearing

Clip

x 6

Release Fork Support

*1

: 37 (375, 27)

*2

: 39 (400, 29)

Flywheel

Clutch Disc

Clutch Cover

ReleaseFork

Boot

1

* : 1ZZ–FE, 3ZZ–FE Engine

2

* : 1CD–FTV Engine

: Specified torque

N·m (kgf·cm, ft·lbf)

D00201

AVENSIS/CORONA SUP (RM781E)

CL–10

CLUTCH

–

CLUTCH UNIT

CL01K–04

REMOVAL

1.

REMOVE TRANSAXLE FROM ENGINE

C50, C250 M/T: See page MX–2

S54, S55 M/T: See page MX–2

E351 M/T: See page MX–2

2.

REMOVE CLUTCH COVER AND DISC

(a) Place matchmarks on the flywheel and clutch cover.

(b) Loosen each set bolt one turn at a time until spring tension

is released.

(c) Remove the set bolts, and pull off the clutch cover with the

clutch disc.

NOTICE:

Do not drop the clutch disc.

Matchmarks

D00202

3.

REMOVE RELEASE BEARING AND FORK FROM

TRANSAXLE

Remove the release bearing with the fork together and then

separate them.

Q01056

AVENSIS/CORONA SUP (RM781E)

CL–11

CLUTCH

–

CLUTCH UNIT

CL01L–04

INSPECTION

1.

INSPECT CLUTCH DISC FOR WEAR OR DAMAGE

Using calipers, measure the rivet head depth.

Minimum rivet depth:

0.3 mm (0.012in.)

If necessary, replace the clutch disc.

Q01057

Q06033

D00203

Z10408

Q01060

2.

INSPECT CLUTCH DISC RUNOUT

Using a dial indicator, check the disc.

Maximum runout:

0.8 mm (0.031 in.)

If necessary, replace the clutch disc runout.

3.

INSPECT FLYWHEEL RUNOUT

Using a dial indicator, check the flywheel runout.

Maximum runout:

0.1 mm (0.004 in.)

If necessary, replace the flywheel.

4.

INSPECT DIAPHRAGM SPRING FOR WEAR

Using calipers, measure the diaphragm spring for depth and

width of wear.

B

A

Maximum runout:

A (Depth): 0.5 mm (0.020 in.)

B (Width): 6.0 mm (0.236 in.)

If necessary, replace the clutch cover.

5.

INSPECT RELEASE BEARING

Turn the bearing by hand while applying force in the axial direc-

tion.

HINT:

The bearing is permanently lubricated and requires no cleaning

or lubrication.

If necessary, replace the release bearing.

AVENSIS/CORONA SUP (RM781E)

CL–12

CLUTCH

–

CLUTCH UNIT

CL01M–04

INSTALLATION

SST

1.

INSTALL CLUTCH DISC AND CLUTCH COVER ON

FLYWHEEL

Flywheel Side

(a) 1CD–FTV Engine:

Insert SST in the clutch disc, and then insert them in the

flywheel.

SST 09301–00210

HINT:

D00682

Take care not to insert clutch disc in the wrong direction.

(b) Others:

Insert SST in the clutch disc, and then insert them in the

flywheel.

SST 09301–00120

HINT:

Take care not to insert clutch disc in the wrong direction.

(c) Align the matchmark on the clutch cover with the one on

the flywheel.

7

SST

1,4

(d) Torque the bolts on the clutch cover in the order shown in

the illustration.

Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

HINT:

3

6

8

Temporarily tighten the No.1 and No.2 bolts.

Matchmarks

2,5

D00204

2.

CHECK DIAPHRAGM SPRING TIP ALIGNMENT

SST

Using a dial indicator with roller instrument, check the dia-

phragm spring tip alignment.

Maximum non–alignment: 0.5 mm (0.020 in.)

If alignment is not as specified, using SST, adjust the dia-

phragm spring tip alignment.

SST 09333–00013

D00205

3.

APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE (NLGI NO.2)

(a) Apply release hub grease to the following parts.

S

Release fork and hub contact point

Release fork and push rod contact point

Release fork pivot point

(b) Apply clutch spline grease.

S

Clutch disc spline

HINT:

Q05807

Recommended grease part number 08887–01706 (100g).

AVENSIS/CORONA SUP (RM781E)

CL–13

CLUTCH

–

CLUTCH UNIT

4.

INSTALL RELEASE BEARING AND FORK TO TRANS-

AXLE

Install the bearing to the release fork, and then install them to

the transaxle.

5.

INSTALL TRANSAXLE TO ENGINE

C50, C250 M/T: See page MX–2

S54, S55 M/T: See page MX–2

E351 M/T: See page MX–2

AVENSIS/CORONA SUP (RM781E)

CLUTCH for Your Toyota Avensis 4 Door First Generation (1997-2003)

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