Get CLUTCH -> Clutch Master Cylinder Guide for Toyota Avensis 4 Door First Generation (1997-2003)

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)

CLUTCH -> Clutch Master Cylinder for Your Toyota Avensis 4 Door First Generation (1997-2003)

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