INSTALLATION
PROCEDURE
1. INSTALL CLUTCH DISC ASSEMBLY
(a) Insert SST into the clutch disc assembly, and then install SST and the clutch disc assembly together to the flywheel sub-assembly.
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Flywheel Sub-assembly Side |
SST: 09301-00220
NOTICE:
Be sure to install the clutch disc assembly so that it is facing in the correct direction.
2. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmarks on the clutch cover assembly with the one on the flywheel sub-assembly. Text in Illustration
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(b) Following the order shown in the illustration, tighten the 6 bolts, starting with the bolt located near the knock pin at the top.
SST: 09301-00220
Torque:
19 N·m {195 kgf·cm, 14 ft·lbf}
HINT:
3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
(a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment. SST: 09333-00013 Maximum non-alignment: 0.5 mm (0.0196 in.) If the alignment is more than the maximum, use SST to adjust the diaphragm spring tip alignment. |
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4. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Install the clutch release fork dust seal to the clutch release fork sub-assembly.
(b) Install the clutch release fork collar to the clutch release fork sub-assembly.
(c) Apply release hub grease to the clutch release fork sub-assembly, clutch release bearing assembly, push rod contact point and pivot points shown in the illustration.
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Release hub grease |
Grease:
Toyota Genuine Release Hub Grease or equivalent
(d) Apply clutch spline grease to the input shaft spline.
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Clutch spline grease |
Grease:
Toyota Genuine Clutch Spline Grease or equivalent
(e) Install the clutch release bearing assembly to the clutch release fork sub-assembly with the clip.
(f) Install the release fork support to the manual transmission assembly.
Torque:
47 N·m {480 kgf·cm, 35 ft·lbf}
(g) Install the clutch release fork sub-assembly with the clutch release bearing assembly to the manual transmission assembly.
HINT:
After installation, move the clutch release fork sub-assembly back and forth to check that the clutch release bearing assembly slides smoothly.
5. INSTALL MANUAL TRANSMISSION ASSEMBLY
(See page
)
Installation
INSTALLATION
PROCEDURE
1. INSTALL FRONT AXLE HUB
2. INSTALL FRONT SUSPENSION UPPER ARM
(a) Install a new nut and clip.
Torque:
110 N·m {1122 kgf·cm, 81 ft·lbf}
3. INSTALL FRONT SUSPENSION LOWER ARM
(a) Install the front suspension lower arm with the 2 bolts.
Torque:
160 N·m {1631 ...
Installation
INSTALLATION
PROCEDURE
1. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new front differential drive pinion bearing spacer.
HINT:
Make sure the front differential drive pinion bearing spacer is installed correctly.
2. INSTALL DIFFERENTIAL OIL STORAGE RING
(a) Using a bra ...
Diagnosis System
DIAGNOSIS SYSTEM
1. CHECK DLC3
(a) The vehicle ECUs use ISO 15765-4 communication protocol. The terminal arrangement
of the DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format.
Terminals No. (Symbols)
Terminal Description
Condition
Spe ...