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 COVER AND DISC CLUTCH SET

(a) Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly. SST: 09301-00230 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.

*1 Clutch Disc Assembly *2 Flywheel Sub-assembly *a Flywheel Sub-assembly Side

(b) Align the matchmarks on the clutch cover assembly with the one on the flywheel sub-assembly.

*a Matchmark *b Temporarily Tighten

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

SST: 09301-00230

Torque:

19.1 N·m {195 kgf·cm, 14 ft·lbf}

2. 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

3. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

(a) Temporarily tighten the bleeder clutch release tube to a new clutch release cylinder with bearing assembly. NOTICE: Do not allow any foreign matter such as dirt or dust to enter the bleeder clutch release tube from the connecting part.

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

(c) Install the clutch release cylinder with bearing assembly with 3 new bolts. Torque: 22.5 N·m {229 kgf·cm, 17 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.

(d) Install the clutch tube boot to the manual transaxle assembly.

(e) Temporarily tighten the bleeder clutch release tube to the clutch release bleeder sub-assembly.

(f) Temporarily tighten the bolt and install the clutch release bleeder sub-assembly. NOTICE: Install the parts so that the rotation prevention tab of the clutch release bleeder sub-assembly is contacting the rib of the manual transaxle assembly.

*a Rotation Prevention Tab

(g) Using a 10 mm union nut wrench, fully tighten the bleeder clutch release tube to the clutch release cylinder with bearing 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. HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here 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

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

Clutch Spline Grease

Grease:

Toyota Genuine Clutch Spline Grease or equivalent

4. INSTALL CLUTCH RELEASE BEARING PLATE

(a) Install a new clutch release bearing plate to the clutch release cylinder with bearing assembly. NOTICE: After installing the clutch release bearing plate to the clutch release cylinder with bearing assembly, check that there are no gaps.

5. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

(a) Disconnect the bleeder clutch release tube from the clutch release bleeder sub-assembly.

(b) Remove the bolt and clutch release bleeder sub-assembly from the manual transaxle assembly.

6. INSPECT CLUTCH PIPE LINE

(a) Using SST, apply pressure of 100 kPa (1.0 kgf/cm2, 15 psi) to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more. SST: 09992-00242 If the pressure drops, replace the bleeder clutch release tube.

7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

(a) Temporarily tighten the bleeder clutch release tube to the clutch release bleeder sub-assembly.

*a Rotation Prevention Tab

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

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

NOTICE:

Install the parts so that the rotation prevention tab of the clutch release bleeder sub-assembly is contacting the rib of the manual transaxle assembly.

(c) Using a 10 mm union nut wrench, fully tighten the bleeder clutch release tube. 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 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 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}

*a Torque Wrench Fulcrum Length

(d) Using a 10 mm union nut wrench, fully tighten 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}

9. INSTALL MANUAL TRANSAXLE ASSEMBLY

Click here

10. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

Click here