CLUTCH MASTER CYLINDER (for LHD) INSTALLATION


  1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY


    1. Install the clutch master cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }
    2. A01DUTFE01
      Text in Illustration
      *1 MP grease

      Apply MP grease to the contact surfaces of the pin and clevis bush.

    3. Connect the clevis to the clutch pedal with the pin.

    4. Install a new clip to the pin.

    5. Install the clutch start switch with the nut.

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }

    6. Using a union nut wrench, connect the flexible tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    7. A01DRM4E01
      Text in Illustration
      *1 Paint Mark
      A01DQPB Top
      A01DMKT Left
      A01DPHJ Rear

      Connect the clutch reservoir hose.

      Tech Tips


      • Make sure the paint mark of the clutch reservoir hose is facing upward.

      • Make sure the direction of the clamp is as shown in the illustration.

  2. INSTALL CLUTCH PEDAL WITH CLUTCH MASTER CYLINDER


    1. Install the clutch pedal with clutch master cylinder to the vehicle with the 2 nuts and bolt.

      Torque:
      for nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      for bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. w/ Cruise Control:

      Connect the clutch switch connector.

    3. Connect the clutch start switch connector.

  3. INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY


    1. Install the driver side junction block Click here.

  4. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE


    1. Using a union nut wrench, connect the flexible hose tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  5. CONNECT CLUTCH RESERVOIR TUBE


    1. A01DS8D

      Connect the clutch reservoir tube.

      Text in Illustration
      A01DQPB Top
      A01DMKT Left

      Tech Tips

      Make sure the direction of the clamp is as shown in the illustration.

  6. FILL RESERVOIR WITH BRAKE FLUID

    A01DROBE01
    Text in Illustration
    *A for LHD (2TR-FE, 5L-E)
    *B for LHD (1GR-FE, 1KD-FTV)
    *C for RHD

    1. Fill the reservoir with brake fluid.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  7. BLEED CLUTCH LINE


    1. Remove the bleeder plug cap of the release cylinder.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  8. CHECK FLUID LEVEL IN RESERVOIR


    1. Check the fluid level.

      If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  9. CHECK FOR BRAKE FLUID LEAK FROM CLUTCH LINE

  10. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY


    1. Fold back the floor carpet.

    2. A01DPGQE02
      Text in Illustration
      *a Pedal Height Adjustment Point
      *b Push Rod Play and Free Play Adjustment Point
      *c Pedal Height

      Check that the pedal height is correct.

      Pedal height from floor
      172.9 to 182.9 mm (6.81 to 7.20 in.)

    3. Adjust the pedal height.


      1. w/ Cruise Control:

        Loosen the lock nut and turn the clutch switch until the height is correct. Tighten the lock nut.

        Torque:
        16 N*m  { 160 kgf*cm, 12 ft.*lbf }

      2. w/o Cruise Control:

        Loosen the lock nut and turn the clutch pedal stopper bolt until the height is correct. Tighten the lock nut.

        Torque:
        26 N*m  { 260 kgf*cm, 19 ft.*lbf }
    4. A01DPOSE09
      Text in Illustration
      *a Pedal Free Play
      *b Push Rod Play

      Check the pedal free play and push rod play.

      Tech Tips

      Pay close attention to the change in resistance to distinguish between pedal free play and push rod play while performing the inspection.


      1. Depress the clutch pedal until resistance is felt.

      2. Measure the distance between the pedal's released position and the position in the previous step.

        Pedal free play
        5.0 to 15.0 mm (0.197 to 0.591 in.)

      3. Release the pedal. Using your finger, gently press the pedal until resistance increases slightly.

      4. Measure the distance between the pedal's released position and the position in the previous step.

        Push rod play at pedal top
        1.0 to 5.0 mm (0.0394 to 0.197 in.)

    5. Adjust the pedal free play and push rod play.

      Tech Tips

      The push rod play can be adjusted by changing the length of the push rod. Pedal free play changes together with push rod play.


      1. Loosen the lock nut and turn the push rod until the pedal free play and push rod play are within the specified ranges.

        Note

        If pedal free play and push rod play are not within the standard range even after adjustment, inspect the related parts.

      2. Tighten the lock nut.

        Torque:
        12 N*m  { 120 kgf*cm, 9 ft.*lbf }

      3. After adjusting the pedal free play and push rod play, check the pedal height.

    6. A01DTVTE24
      Text in Illustration
      *a Full Stroke End Position
      *b Release Position
      *c 25 mm or more

      Check the clutch release point.


      1. Pull the parking brake lever and use wheel chocks to stabilize the vehicle.

      2. Start the engine and run it at idle.

      3. Without depressing the clutch pedal, slowly move the shift lever to R until the gears contact.

      4. Gently depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.

        Standard distance
        25 mm (0.984 in.) or more

        If the result is not as specified, perform the following procedures.


        • Check pedal height.


        • Check push rod play and pedal free play.


        • Bleed air from clutch line.


        • Check clutch cover and disc.