CLUTCH RELEASE CYLINDER (for 1AD-FTV, 2AD-FHV) INSTALLATION


  1. INSTALL CLUTCH RELEASE CYLINDER KIT


    1. A01IPS8E04

      Coat a new piston with lithium soap base glycol grease as shown in the illustration.

    2. Install the piston and a new spring to the cylinder body.

      Note

      Do not damage the inside of the cylinder body.

      Tech Tips

      Install the smaller end of the spring to the piston.

    3. Install a new boot to the push rod.

    4. Install the push rod together with the boot to the cylinder body.

  2. TEMPORARILY INSTALL RELEASE CYLINDER BLEEDER PLUG


    1. A01IRG0E02

      Install the release cylinder bleeder plug to the cylinder body.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Install the bleeder plug cap to the bleeder plug.

  3. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01IR3U

      Install the clutch release cylinder and No. 1 clutch tube bracket with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  4. CONNECT CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE


    1. A01IRA8

      Using a union nut wrench, connect the clutch release cylinder to accumulator 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. INSTALL BATTERY TRAY

  6. INSTALL BATTERY

  7. INSTALL BATTERY INSULATOR

  8. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Attach the hook of the battery clamp sub-assembly to the battery carrier.

    2. Partially tighten the nut and temporarily install the bolt.

    3. Adjust the battery clamp sub-assembly position.

    4. Tighten the nut and bolt.

      Torque:
      for bolt
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }
      for nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  9. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  11. BLEED CLUTCH LINE

    for 1AD-FTV: Click here

    for 2AD-FHV: Click here

  12. INSPECT FLUID LEVEL


    1. A01INQ3

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

  13. INSPECT FOR FLUID LEAK

    Tech Tips

    Check for leaks in the clutch system.