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

CL–9

CLUTCH

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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

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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 -> Clutch Unit for Your Toyota Avensis 4 Door First Generation (1997-2003)

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