Last Modified: 07-31-2024 6.11:8.1.0 Doc ID: RM100000001C4LL
Model Year Start: 2019 Model: Corolla Hatchback Prod Date Range: [06/2018 - 09/2022]
Title: CLUTCH: CLUTCH UNIT (for EG60): INSTALLATION; 2019 - 2022 MY Corolla Corolla Hatchback [06/2018 - 09/2022]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

When the manual transaxle assembly is removed, be sure to use a new clutch release cylinder with bearing assembly and new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release cylinder with bearing assembly to return to its original position. Dust from the moving section may damage the seal of the clutch release cylinder with bearing assembly, possibly causing clutch fluid leaks.

PROCEDURE

1. INSTALL CLUTCH DISC ASSEMBLY

*1

Clutch Disc Assembly

*2

Flywheel Sub-assembly

*a

Flywheel Sub-assembly Side

(a) Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.

SST: 09301-00210

NOTICE:

  • Keep the lined part of the clutch disc assembly, the pressure plate, and the surface of the flywheel sub-assembly away from oil and foreign matter.
  • Insert the clutch disc assembly in the correct direction.

2. INSTALL CLUTCH COVER ASSEMBLY

*a

Matchmark

*b

Temporarily Tighten

(a) Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.

(b) Following the procedure shown in the illustration, fully tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

SST: 09301-00210

Torque:

19.1 N·m {195 kgf·cm, 14 ft·lbf}

HINT:

  • Following the order in the illustration, fully tighten the bolts evenly one at a time.
  • Move SST up and down, right and left lightly after checking that the clutch disc assembly is in the center, and tighten the bolts.

3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

(a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

Maximum Non-alignment:

0.5 mm (0.0197 in.)

(b) If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.

SST: 09333-00013

4. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY TO BLEEDER TUBE

(a) Install the clamp to a new clutch release cylinder with bearing assembly to bleeder tube.

(b) Temporarily tighten the clutch release cylinder with bearing assembly to bleeder tube to the clutch release bleeder sub-assembly.

(c) Temporarily tighten the clamp to the clutch release cylinder with bearing assembly to bleeder tube.

NOTICE:

Make sure that the paint mark of the clutch release cylinder with bearing assembly to bleeder tube is within the location shown in the illustration.

*a

Paint Mark

5. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

(a) Clean and degrease all installation surfaces for the clutch release cylinder with bearing assembly.

(b) Install a new clutch release cylinder with bearing assembly to the manual transaxle assembly with 2 new bolts as shown in the illustration.

*1

Clutch Release Cylinder with Bearing Assembly

-

-

*a

Boot

*b

Dust Bellows

Torque:

14 N·m {143 kgf·cm, 10 ft·lbf}

NOTICE:

  • The clutch release cylinder with bearing assembly and installation bolts cannot be reused and must be replaced with new ones.
  • Clean and degrease all installation surfaces and make sure that the clutch release cylinder with bearing assembly fits securely with the manual transaxle assembly during installation. The first bolt should be tightened by hand while holding the clutch release cylinder with bearing assembly.
  • Ensure that none of the clutch spline grease adheres to the clutch release cylinder with bearing assembly.
  • The clutch release cylinder with bearing assembly cannot be disassembled.
  • Make sure that the boot is not flipped back.
  • Do not hold the clutch release cylinder with bearing assembly by the dust bellows. If the dust bellows is displaced, moisture or foreign matter may enter and degrade operational performance.

(c) Apply clutch spline grease to the input shaft splines.

Clutch Spline Grease

Grease:

Toyota Genuine Clutch Spline Grease or equivalent

6. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

(a) Connect the clutch release cylinder with bearing assembly to bleeder tube to the adapter.

NOTICE:

  • Confirm that the adapter makes a "click" sound when pushed.
  • Check that the clutch release cylinder with bearing assembly to bleeder tube and adapter are securely connected by pulling on them.
  • When connecting the bleeder tube to the adapter of the clutch release cylinder with bearing assembly, hold the back of the adapter to support it.

*1

Clutch Release Cylinder with Bearing Assembly to Bleeder Tube

*a

Adapter

(b) Install the clutch release bleeder sub-assembly to the manual transaxle assembly with the bolt as shown in the illustration.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(c) Fully tighten the bolt.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(d) Using a 10 mm union nut wrench, install the clutch release cylinder with bearing assembly to bleeder tube to the clutch release bleeder sub-assembly.

Torque:

Specified Tightening Torque :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

NOTICE:

Do not kink or damage the clutch release cylinder to flexible hose tube.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here 2019 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

  • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

    13.4 N*m (137 kgf*cm, 10 ft.*lbf)

*a

Torque Wrench Fulcrum Length

7. INSTALL BLEEDER TO FLEXIBLE HOSE TUBE

(a) Install the clamp to the bleeder to flexible hose tube.

(b) Temporarily tighten the bleeder to flexible hose tube to the clutch release bleeder sub-assembly.

(c) Install the bleeder to flexible hose tube to the manual transaxle assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Using a 10 mm union nut wrench, install the bleeder to flexible hose tube to the clutch release bleeder sub-assembly.

Torque:

Specified Tightening Torque :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

NOTICE:

  • Do not kink or damage the bleeder clutch release tube.
  • Do not allow any foreign matter such as dirt or dust to enter the bleeder clutch release tube from the connecting part.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here 2019 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

  • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

    13.4 N*m (137 kgf*cm, 10 ft.*lbf)

*a

Torque Wrench Fulcrum Length

8. INSTALL MANUAL TRANSAXLE ASSEMBLY

Click here 2019 MY Corolla Corolla Hatchback [06/2018 - 01/2019]; EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE ASSEMBLY: INSTALLATION 2020 MY Corolla Corolla Hatchback [01/2019 - 03/2019]; EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE ASSEMBLY: INSTALLATION 2020 - 2021 MY Corolla Corolla Hatchback [03/2019 - 06/2021]; EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE ASSEMBLY: INSTALLATION 2022 MY Corolla Corolla Hatchback [06/2021 - 09/2022]; EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE ASSEMBLY: INSTALLATION