Toyota Camry

 XV30 (2002–2006) Service Manual

Clutch
Clutch pedal sub-assy

REPLACEMENT

1. REMOVE INSTRUMENT CLUSTER FINISH PANEL

2. REMOVE COMBINATION METER ASSEMBLY

3.  REMOVE INSTRUMENT PANEL SUB−ASSY UPPER

4. REMOVE INSTRUMENT PNL INSERT SUB−ASSY LWR LH

5. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN

a. Remove the clip and hole pin.

6. REMOVE CLUTCH PEDAL ASSY

1. Disconnect the clutch start switch clamp and connector.

2. Remove the bolt, 2 nuts and clutch pedal assy.

Remove clutch pedal assy

7. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING

1. Using a small screwdriver, remove the E−ring.

2.  Remove the compression spring.

Remove turn over spring seat compression spring

8. REMOVE CLUTCH PEDAL SUB−ASSY

1. Remove the clutch pedal spring.

2. Mount the clutch pedal assy in a soft jaw vise.

c. Remove the bolt, nut and clutch pedal sub−assy from clutch pedal support.

9. REMOVE CLUTCH PEDAL BUSH

a. Remove the 2 bushes from the clutch pedal sub−assy.

Remove clutch pedal bush

10. REMOVE CLUTCH PEDAL TURNOVER BUSH

11. REMOVE OVER CENTER SPRING CAP

12. REMOVE CLUTCH PEDAL PAD

13.  REMOVE CLUTCH PEDAL No.1 CUSHION

14. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH

a. Using a hexagon wrench (8 mm) and hammer, remove the clevis bush from the clutch pedal sub−assy.

Remove clutch master cylinder push rod clevis bush

15. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH

1.  Apply MP grease to inside of a new bush.

2.  Install the clevis bush to the clutch pedal sub−assy.

   HINT: Install the clevis bush from the right side of the vehicle.

Install clutch master cylinder push rod clevis bush

16.  INSTALL CLUTCH PEDAL No.1 CUSHION

17. INSTALL CLUTCH PEDAL PAD

18. INSTALL OVER CENTER SPRING CAP

19. INSTALL CLUTCH PEDAL TURNOVER BUSH

1. Apply MP grease to inside of a new bush.

2. Install the bush to the clutch pedal sub−assy.

20. INSTALL CLUTCH PEDAL BUSH

1. Apply MP grease to both side of 2 new bushes.

2.  Install the 2 bushes to the clutch pedal sub−assy.

Install clutch pedal bush

21. INSTALL CLUTCH PEDAL SUB−ASSY

a. Install the clutch pedal sub−assy to the clutch pedal support with the bolt and nut.

Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)

HINT: Install the bolt from the right side of the vehicle.

b. Install the clutch pedal spring.

22. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING

1. Apply MP grease to the contact surface of the bush and spring.

2. Install the compression spring.

3. Using needle nose pliers, install the E−ring.

Install turn over spring seat compression spring

23. INSTALL CLUTCH PEDAL ASSY

1.  Install the clutch pedal assy with the bolt and 2 nuts.

   Torque:
   Bolt: 19 N·m (195 kgf·cm, 14 ft·lbf) Nut: 12 N·m (120 kgf·cm, 9 ft·lbf)

2.  Connect the clutch start switch clamp and connector.

24. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN

1. Apply MP grease to the contact surface of the hole pin and bush.

2. Connect the clevis to the clutch pedal assy with the hole pin.

   HINT: Install the hole pin from the left side of the vehicle.

3. Install the clip to the hole pin.

Install clutch master cylinder push rod clevis w/hole pin

25. INSTALL INSTRUMENT PNL INSERT SUB−ASSY LWR LH

26. INSTALL INSTRUMENT PANEL SUB−ASSY UPPER

27. INSTALL COMBINATION METER ASSEMBLY

28. INSTALL INSTRUMENT CLUSTER FINISH PANEL

29. INSPECT AND ADJUST CLUTCH PEDAL SUB−ASSY

30. INSPECT CLUTCH START SWITCH ASSY

Clutch system (From July, 2003)

Clutch release cylinder assy

Clutch accumulator assy

Clutch unit

Clutch start switch assy

Clutch pedal sub-assy

Clutch start switch assy

Clutch pedal sub-assy

Clutch master cylinder assy