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Toyota Corolla (2004+). Manual - part 33

42-14

CLUTCH

- CLUTCH RELEASE CYLINDER ASSY (MTM)

CLUTCH RELEASE CYLINDER ASSY (MTM)

4203Q-01

COMPONENTS

5.0 (51, 44 in. lbf)

15.2 (155, 11)

Flexible Hose Tube

11.8 (120, 9)

Bracket

Bleeder Plug

8.4 (85, 74 in. lbf)

Release Cylinder Bleeder Plug Cap

Release Cylinder Body

Piston

Push Rod

F Spring

Boot

Nm (kgfcm, ftlbf)

: Specified torque

F Non-reusable part

Lithium soap base glycol grease

D11545

42-15

CLUTCH

- CLUTCH RELEASE CYLINDER ASSY (MTM)

4203R-01

OVERHAUL

DRAIN CLUTCH FLUID

DISCONNECT CLUTCH RELEASE CYLINDER TO

FLEXIBLE HOSE TUBE

(a) Using SST, disconnect the flexible hose tube.

SST

09023-00100

HINT:

Use a container to catch the fluid.

SST

D26809

REMOVE CLUTCH RELEASE CYLINDER ASSY

(a) Remove the 3 bolts, clutch release cylinder assy and

clutch line bracket.

D26810

REMOVE CLUTCH RELEASE CYLINDER KIT

(a) Remove the boot from the cylinder body.

(b) Remove the push rod from the cylinder body.

(c)

Remove the piston from the cylinder body.

NOTICE:

Be careful not to damage the inside of the cylinder body.

(d) Remove the spring from the cylinder body.

(e) Remove the bleeder plug cap from the bleeder plug.

REMOVE RELEASE CYLINDER BLEEDER PLUG

INSTALL RELEASE CYLINDER BLEEDER PLUG

Torque: 8.4 N m (85 kgf cm, 74 in. lbf)

42-16

CLUTCH

- CLUTCH RELEASE CYLINDER ASSY (MTM)

INSTALL CLUTCH RELEASE CYLINDER KIT

(a) Install the bleeder plug cap to the bleeder plug.

(b) Install a new spring to the cylinder body.

(c)

Coat parts with lithium soap base glycol grease, as shown

in the illustration.

(d) Install the piston to the cylinder body.

NOTICE:

Be careful not to damage the inside of the cylinder body.

(e) Install the push rod to the cylinder body.

(f)

Install the boot to the cylinder body.

CL0672

INSTALL CLUTCH RELEASE CYLINDER ASSY

(a) Install the clutch release cylinder and clutch line bracket

with the 2 bolts.

Torque: 11.8 N m (120 kgf cm, 9 ft lbf)

(b) Install the flexible hose tube with the bolt.

Torque: 5.0 N m (51 kgf cm, 44 in. lbf)

D26810

CONNECT CLUTCH RELEASE CYLINDER TO

FLEXIBLE HOSE TUBE

(a) Using SST, connect the flexible hose tube.

SST

09023-00100

Torque: 15.2 N m (155 kgf cm, 11 ft lbf)

SST

D26809

10. BLEED CLUTCH PIPE LINE

(a) Fill the brake reservoir tank with brake fluid and bleed clutch system.

Torque: 8.4 N m (85 kgf cm, 74 in. lbf)

11. CHECK CLUTCH FLUID LEAKAGE

42-23

CLUTCH

- CLUTCH START SWITCH ASSY (MTM)

42029-02

INSPECTION

INSPECT CLUTCH START SWITCH ASSY

(a) Check the continuity between the terminals when the

switch is ON and OFF.

Switch position

Condition

ON (pushed)

Continuity

OFF (free)

No continuity

8.0

0.5 mm

(0.315

0.020 in.)

D11485

42-22

CLUTCH

- CLUTCH START SWITCH ASSY (MTM)

CLUTCH START SWITCH ASSY (MTM)

42028-02

ON-VEHICLE INSPECTION

CHECK CLUTCH START SYSTEM

(a) Check that the engine does not start when the clutch ped-

al is released.

(b) Check that the engine starts when the clutch pedal is fully

depressed.

If necessary, replace the clutch start switch assy.

Clutch Start Switch

Assy

D26340

42-24

CLUTCH

- CLUTCH START SWITCH ASSY (MTM)

4203U-01

REPLACEMENT

REMOVE CLUTCH START SWITCH ASSY

(a) Disconnect the clutch start switch assy connector.

(b) Remove the nut and clutch start switch assy from the clutch pedal support.

INSTALL CLUTCH START SWITCH ASSY

(a) Install the clutch start switch assy with the nut.

Torque: 15.68 N m (160 kgf cm, 12 ft lbf)

(b) Connect the clutch start switch assy connector.

INSPECT CLUTCH START SWITCH ASSY (See page 42-22)

42-17

CLUTCH

- CLUTCH UNIT (MTM)

CLUTCH UNIT (MTM)

4203S-01

COMPONENTS

Clutch Disc Assy

19.1 (195, 14)

Clutch Release

Fork Sub-assy

Clutch Release

Bearing Assy

Release Bearing

Hub Clip

Flywheel Sub-assy

Clutch Cover Assy

Release Fork Support

36.8 (375, 27)

Clutch Release Fork Boot

Nm (kgfcm, ftlbf)

: Specified torque

Clutch spline grease

Release hub grease

D26321

42-18

CLUTCH

- CLUTCH UNIT (MTM)

4203T-01

OVERHAUL

REMOVE MANUAL TRANSAXLE ASSY (See page 41-17)

REMOVE CLUTCH RELEASE FORK SUB-ASSY

(a) Remove the clutch release fork with clutch release bear-

ing from the transaxle assy.

Q01056

REMOVE CLUTCH RELEASE BEARING ASSY

(a) Remove the clutch release bearing assy from the clutch release fork.

REMOVE RELEASE FORK SUPPORT

(a) Remove the release fork support from the transaxle assy.

REMOVE RELEASE BEARING HUB CLIP

REMOVE CLUTCH RELEASE FORK BOOT

REMOVE CLUTCH COVER ASSY

(a) Align the matchmarks on the clutch cover assy with the

one on the flywheel sub-assy.

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

is released.

(c)

Remove the 6 bolts, and pull off the clutch cover assy.

NOTICE:

Do not drop the clutch disc assy.

C62955

Matchmarks

D25280

REMOVE CLUTCH DISC ASSY

NOTICE:

Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub-assy

away from oil and foreign attachment.

INSPECT CLUTCH DISC ASSY

(a) Using vernier calipers, measure the rivet head depth.

Maximum rivet depth: 0.3 mm (0.012 in.)

If necessary, replace the clutch disc assy.

(b) Install the clutch disc assy to the transaxle assy.

NOTICE:

Take care not to insert the clutch disc assy in the wrong

direction.

C62956

42-19

CLUTCH

- CLUTCH UNIT (MTM)

(c)

Using a dial indicator, check the clutch disc assy runout.

Minimum runout: 0.8 mm (0.031 in.)

Transaxle

If necessary, replace the clutch disc assy.

Side

D26338

10. INSPECT CLUTCH COVER ASSY

(a) Using vernier calipers, inspect the diaphragm spring for

depth and width of wear.

Maximum:

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

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

If necessary, replace clutch cover assy.

C57466

D25281

11. INSPECT FLYWHEEL SUB-ASSY

(a) Using a dial indicator, inspect the flywheel sub-assy run-

out.

Maximum runout: 0.1 mm (0.004 in.)

If necessary, replace the flywheel sub-assy.

C62958

12. INSPECT CLUTCH RELEASE BEARING ASSY

(a) Turn the release bearing by hand while applying force in

the axial direction.

HINT:

The bearing is permanently lubricated and requires no cleaning

or lubrication.

If necessary, replace the release bearing assy.

Q01060

13. INSTALL CLUTCH DISC ASSY

(a) Insert SST in the clutch disc assy, then insert them in the

flywheel sub-assy.

SST

09301-00210

Flywheel Side

NOTICE:

Take care not to insert clutch disc assy in the wrong direc-

tion.

SST

D26339

42-20

CLUTCH

- CLUTCH UNIT (MTM)

14. INSTALL CLUTCH COVER ASSY

1 (Temporally), 4

SST

(a) Align the matchmarks on the clutch cover assy and fly-

wheel sub-assy.

(b) Following the procedures shown in the illustration, tighten

the 6 bolts, in the order starting the bolt locating near the

knock pin on the top.

Torque: 19.1 N m (195 kgf cm, 14 ft lbf)

HINT:

Matchmarks

D26323

Following the order in the illustration, tighten the bolts at

a time evenly.

Move SST up and down, right and left lightly, after check-

ing that the disc is in the center, tighten the bolts.

15. INSPECT AND ADJUST CLUTCH COVER ASSY

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

SST

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

16.

INSTALL RELEASE FORK SUPPORT

(a)

Install the release fork support to the transaxle assy.

Torque: 36.8 N m (375 kgf cm, 27 ft lbf)

17.

INSTALL RELEASE BEARING HUB CLIP

18. INSTALL CLUTCH RELEASE FORK SUB-ASSY

(a) Apply release hub grease to the release fork and release

bearing assy contact, release fork and push rod contact

and release fork pivot points.

Sealant:

Part No. 08887-01806, RELEASE HUB GREASE or

equivalent

(b) Install the release fork to the release bearing assy.

Release hub grease

D27398

19.

INSTALL CLUTCH RELEASE BEARING ASSY

(a)

Apply the clutch spline grease to the input shaft spline.

Sealant:

Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent

(b)

Install the bearing to the release fork, and then install them to the transaxle assy.

NOTICE:

After the installation, move the folk forward and backward to check that the release bearing slides

smoothly.

42-21

CLUTCH

CLUTCH UNIT (MTM)

20. INSTALL CLUTCH RELEASE FORK BOOT

21. INSTALL MANUAL TRANSAXLE ASSY (See page

41-17)

42-1

CLUTCH

- CLUTCH SYSTEM (MTM)

CLUTCH SYSTEM (MTM)

4203K-01

PROBLEM SYMPTOMS TABLE

HINT:

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

cause of the problem. Check each part in order. If necessary, replace these parts.

Symptom

Suspect Area

See page

5. Engine mounting (Loosen)

6. Clutch disc assy (Runout is excessive)

42-18

7. Clutch disc assy (Oily)

42-18

Clutch grabs/chatters

8. Clutch disc assy (Worn out)

42-18

9. Clutch disc torsion rubber (Damaged)

42-18

10.Clutch disc assy (Glazed)

42-18

11.Diaphragm spring (Out of tip alignment)

1. Clutch Line (Air in line)

Clutch pedal spongy

2. Master cylinder cup (Damaged)

42-10

3. Release cylinder rubber (Damaged)

42-15

1. Clutch release bearing assy (Worn, dirty, or damaged)

42-15

Clutch noisy

2. Clutch disc torsion rubber (Damaged)

42-18

1. Clutch pedal (Free play out of adjustment)

42-2

2. Clutch disc assy (Oily)

42-18

3. Clutch disc assy (Worn out)

42-18

Clutch slips

4. Diaphragm spring (Damaged)

42-18

5. Pressure plate (Distortion)

42-18

6. Flywheel sub-assy (Distortion)

1. Clutch pedal (Free play out of adjustment)

42-2

2. Clutch line (Air in line)

3. Master cylinder cup (Damaged)

42-10

4. Release cylinder cup (Damaged)

42-15

5. Clutch disc assy (Out of true)

42-18

Clutch does not disengage

6. Clutch disc assy (Runout of excessive)

42-18

7. Clutch disc assy (Lining broken)

42-18

8. Clutch disc assy (Dirty or burned)

42-18

9. Clutch disc assy (Oily)

42-18

10.Clutch disc assy (Lack of spline grease)

42-18

50-3

STEERING COLUMN

- STEERING

5000P-03

ON-VEHICLE INSPECTION

CHECK STEERING WHEEL FREEPLAY

(a) Stop the vehicle and face the tires straight ahead.

(b) Rock the steering wheel gently up and down by your

hand, check the steering wheel freeplay.

Maximum freeplay: 30 mm (1.18 in.)

F42427

50-1

STEERING COLUMN

- STEERING

STEERING SYSTEM

5003T-01

PRECAUTION

HANDLING PRECAUTIONS ON STEERING SYSTEM

(a) Care must be taken when replacing parts. Incorrect replacement may affect the performance of the

steering system and result in a driving hazard.

HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM

(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front

passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS

to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (in-

cluding removal or installation of parts, inspection or replacement), be sure to read the precautionary

notice for the supplemental restraint system (See page 60-1).

50-4

STEERING COLUMN

- STEERING

5002Q-02

REPAIR

STEERING OFF CENTER REPAIR PROCEDURE

(a) Inspect steering wheel off center.

Steering Wheel

(1)

Apply masking tape on the top center of the steering

Masking Tape

wheel and steering column upper cover.

(2)

Driving the vehicle on a straight line for 100 meters

Steering Column

at a constant speed of 35 mph (56 km/h), and hold

Upper Cover

the steering wheel to maintain the course.

F16015

(3)

Draw a line on the masking tape as shown in the il-

Steering Column

Upper Cover

lustration.

Marked Line

Steering Wheel

Masking

Tape

F16016

(4)

Turn the steering wheel to its straight position.

Steering Column

HINT:

Upper Cover

Refer to the upper surface of the steering wheel, steering spoke

Marked Line

and SRS airbag line for the straight position.

Steering Wheel

(5)

Draw a new line on the masking tape or the steering

wheel as shown in the illustration.

(6)

Measure the distance between the 2 lines on the

masking tape of the steering wheel.

F16017

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