CLUTCH UNIT(for EC62) INSTALLATION

PROCEDURE

PRECAUTION

Note

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

INSTALL CLUTCH DISC ASSEMBLY

Text in Illustration
*1	Clutch Disc Assembly
*2	Flywheel Sub-assembly

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

SST: 09301-00210

Note

Insert clutch disc assembly in the correct direction.

INSTALL CLUTCH COVER ASSEMBLY
1. Text in Illustration
  
  *a Matchmark
  
  *b Temporarily
  
  Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.
2. Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.
  
  SST
  
  09301-00210
  
  Torque:
  
  19 N*m { 195 kgf*cm, 14 ft.*lbf }
  Tech Tips
  - Following the order in the illustration, tighten the bolts evenly one at a time.
  - Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
1. Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.
  
  Maximum non-alignment
  
  0.5 mm (0.0197 in.)
2. If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
  
  SST
  
  09333-00013
INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY
1. Temporarily tighten the clutch release cylinder to bleeder tube to a new clutch release cylinder with bearing assembly.
  
  Note
  
  Do not allow any foreign matter such as dirt or dust to enter the clutch release cylinder to bleeder tube from the connecting part.
2. Clean and degrease all installation surfaces for the clutch release cylinder with bearing assembly.
3. Install the clutch release cylinder with bearing assembly with 3 new bolts.
  
  Torque:
  
  22.5 N*m { 229 kgf*cm, 17 ft.*lbf }
  Note
  - 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 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.
4. Install the clutch tube boot onto the manual transaxle assembly.
5. Temporarily tighten the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.
6. Temporarily tighten the 2 bolts and install the clutch release bleeder sub-assembly.
7. *a Torque Wrench Fulcrum Length
  
  Using a 10 mm union nut wrench, install the clutch release cylinder to bleeder tube to the clutch release cylinder with bearing assembly.
  
  Torque:
  
  Specified Tightening Torque
  
  15.2 N*m { 155 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Do not kink or damage the clutch release cylinder to bleeder tube.
  Tech Tips
  
  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)
8. Clutch Spline Grease
  
  Apply clutch spline grease to the input shaft splines.
  
  Grease
  
  Toyota Genuine Clutch Spline Grease or equivalent
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
1. Separate the clutch release cylinder to bleeder tube from the clutch release bleeder sub-assembly.
2. Remove the 2 bolts and clutch release bleeder sub-assembly.
INSPECT CLUTCH PIPE LINE
1. 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 clutch release cylinder to flexible hose tube.
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
1. *a Torque Wrench Fulcrum Length
  
  Temporarily tighten the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.
2. Install the clutch release bleeder sub-assembly with the 2 bolts.
  
  Torque:
  
  16.7 N*m { 170 kgf*cm, 12 ft.*lbf }
3. Using a 10 mm union nut wrench, install the clutch release cylinder to bleeder tube.
  
  Torque:
  
  Specified Tightening Torque
  
  15.2 N*m { 155 kgf*cm, 11 ft.*lbf }
  Note
  - Do not kink or damage the clutch release cylinder to bleeder tube.
  - Do not allow any foreign matter such as dirt or dust to enter the clutch release cylinder to bleeder tube from the connecting part.
  Tech Tips
  - 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)
INSTALL CLUTCH FLEXIBLE HOSE BRACKET
1. Install the clutch flexible hose bracket to the manual transaxle assembly with the bolt.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for 2NR-FKE)
1. *a Torque Wrench Fulcrum Length
  
  Using a 10 mm union nut wrench, install the clutch release cylinder 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 }
  Note
  - Do not kink or damage the clutch release cylinder to flexible hose tube.
  - Do not allow any foreign matter such as dirt or dust to enter the clutch release cylinder to flexible hose tube from the connecting part.
  Tech Tips
  - 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)
2. Install the tube clamp to the manual transaxle assembly with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for 2ZR-FE)
1. Install the clamp to the clutch release cylinder to flexible hose tube.
2. *a Torque Wrench Fulcrum Length
  
  Using a 10 mm union nut wrench, install the clutch release cylinder 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 }
  Note
  - Do not kink or damage the clutch release cylinder to flexible hose tube.
  - Do not allow any foreign matter such as dirt or dust to enter the clutch release cylinder to flexible hose tube from the connecting part.
  Tech Tips
  - 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)
3. Install the tube clamp to the manual transaxle assembly with the bolt.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL NO. 1 CLUTCH HOUSING COVER
1. Install the No. 1 clutch housing cover to the manual transaxle assembly.
INSTALL MANUAL TRANSAXLE ASSEMBLY
- When Using the Engine Support Bridge:
  
  Click here
- When Not Using the Engine Support Bridge:
  
  Click here

Text in Illustration
*a	Matchmark
*b	Temporarily