Toyota Camry

 XV30 (2002–2006) Service Manual

Clutch
Clutch release cylinder assy

OVERHAUL

1. DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

1. Remove the bolt and separate the tube clamp bracket.

2. Using SST, disconnect the 2 flexible hose tubes.

   SST 09023−00101 HINT: Use a container to catch the fluid.

2. REMOVE CLUTCH ACCUMULATOR ASSY

1. Remove the 2 bolts and flexible hose bracket No.2.

2. Remove the 2 nuts and the clutch accumulator assy.

3. REMOVE CLUTCH RELEASE CYLINDER ASSY

a. Remove the 2 bolts and clutch release cylinder assy.

4. REMOVE CLUTCH RELEASE CYLINDER KIT

1. Remove the boot from the cylinder body.

2. Remove the push rod from the cylinder body.

3.  Remove the piston from the cylinder body.

NOTICE: Be careful not to damage the inside of the cylinder body.

4.  Remove the spring from the cylinder body.

5. Remove the bleeder plug cap from the bleeder plug.

5. REMOVE RELEASE CYLINDER BLEEDER PLUG

6. INSTALL RELEASE CYLINDER BLEEDER PLUG

   Torque: 8.3 N·m (85 kgf·cm, 73 in.·lbf)

7. INSTALL CLUTCH RELEASE CYLINDER KIT

1.  Install the bleeder plug cap to the bleeder plug.

2. Install a new spring to the cylinder body.

3.  Coat the piston with lithium soap base glycol grease, as shown in the illustration.

4. Install the piston to the cylinder body.

NOTICE: Be careful not to damage the inside of the cylinder body.

5.  Install the push rod to the cylinder body.

6. Install the boot to the cylinder body.

8. INSTALL CLUTCH RELEASE CYLINDER ASSY

a. Install the clutch release cylinder assy with the 2 bolts.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

9. INSTALL CLUTCH ACCUMULATOR ASSY

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

   Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

2.  Install the flexible hose bracket No.2 with the 2 bolts.

   Torque: Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf) Bolt B: 39 N·m (398 kgf·cm, 29 ft·lbf)

10. CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

1. Using SST, connect the 2 flexible hose tubes.

   SST 09023−00101 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

2.  Install the tube clamp bracket with the bolt.

   Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

11. BLEED CLUTCH PIPE LINE

a. Fill the brake reservoir tank with clutch fluid and bleed the clutch system.

Torque: 8.3 N·m (85 kgf·cm, 73 in.·lbf)

12. CHECK CLUTCH FLUID LEAKAGE

13.  CHECK FLUID LEVEL IN RESERVOIR

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