Removal (Camry & Camry Solara) 1. Mark location of hood bracket and bolts for installation reference. Remove hood. Disconnect negative battery cable and wait at least 90 seconds before working on vehicle. Remove battery. Remove air cleaner case with air intake hose. If equipped with cruise control, disconnect cruise control connector. Remove 3 bolts, cruise control bracket and actuator. Remove starter wire connectors. Remove 2 bolts and starter. 2. On V6 models, remove 2 bolts, clutch release cylinder with hoses attached and secure aside. Remove 2 bolts and nut and remove clutch accumulator. Remove 2 bolts and clutch hydraulic line bracket. On all models, disconnect ground straps from transmission. Remove 2 bolts and exhaust manifold stay. On V6 models, disconnect engine wire harness from clamp. On all models, disconnect vehicle speed sensor and back-up light switch connectors. Remove 2 clips, washers and control cables from transaxle. Remove upper transaxle mounting bolts. 3. Raise and support vehicle. Remove front wheels. Remove rear engine dust shield. Drain transaxle fluid. Remove axle shafts from transaxle. See appropriate FWD AXLE SHAFTS article in DRIVE AXLES. Remove 2 bolts, nut and exhaust pipe bracket. Remove front exhaust pipe and catalytic converter. Discard exhaust pipe gaskets and exhaust pipe-to-exhaust manifold flange nuts. 4. Disconnect stabilizer bar link and bracket. Remove fuel line cover. Disconnect outer tie rod ends from steering knuckle. Support steering gear so steering gear remains in place. Remove steering gear-to-crossmember bolts/nuts. If vehicle is equipped with power steering, DO NOT remove power steering lines. 5. On V6 models, remove 2 bolts and front engine mount-to-transaxle damper. Remove right side exhaust manifold support. On all models, remove 3 engine front side mount Silver or Green mounting bolts. Remove 2 hole plugs, nut, 3 bolts and engine left mounting insulator and bracket. 6. Remove hole plug and engine rear side mounting nuts. Install engine support brace. Secure engine to support brace. Remove front subframe suspension member-to-body bolts. Using a hoist, slightly raise engine to remove weight from engine mounts. 7. Remove hole plug and rear engine mount-to-subframe suspension member nuts. Disconnect power steering return pipe clamps from subframe. Remove fender liners. Remove bolts/nuts and subframe suspension member located below engine and transaxle. 8. Using a transmission jack, support transaxle. On 4-cylinder models, remove left stiffener plate. Remove right stiffener plate and intake manifold brace. On all models, remove lower cover plate. Remove remaining transaxle-to-engine bolts. Slightly lower left side of engine and remove transaxle. 9. Place reference mark on clutch cover and flywheel for reassembly reference. Alternately loosen clutch cover bolts until spring tension is released. 10. Remove clutch cover and clutch disc. Remove clutch release fork and clutch release bearing as an assembly from transaxle (if necessary). See Fig. 8 . Disassemble clutch release fork and clutch release bearing (if necessary).
Inspection (Camry & Camry Solara) 1. Check wear on facings of clutch disc by measuring depth of each rivet head. Minimum depth at any rivet is .012" (.30 mm). Using a dial indicator, measure clutch disc runout. Replace clutch disc if runout is greater than .031" (.79 mm). 2. Using a dial indicator, check flywheel runout. Replace flywheel if runout is greater than .004" (.10 mm). 3. Measure depth and wear on diaphragm spring on clutch cover. See Fig. 9 . Maximum depth is .024" (.61 mm) and maximum width is .197" (5.00 mm). Replace clutch cover if necessary. 4. Ensure clutch release bearing rotates smoothly while applying force in axial direction. Replace clutch release bearing if necessary. 5. Using a dial indicator, check diaphragm spring tip runout. If diaphragm spring tip runout is greater than .02" (.5 mm), adjust or replace clutch cover.
Installation (Camry & Camry Solara) 1. When installing flywheel (if removed), flywheel bolt threads are pre-coated from manufacturer. If bolt threads are not pre-coated, apply thread sealant to bolt threads before installing. Install and alternately tighten flywheel bolts in a crisscross pattern to specification. See TORQUE SPECIFICATIONS . 2. Install clutch disc in clutch cover. Align reference marks on clutch cover and flywheel. Install clutch disc and clutch cover on flywheel. 3. Using a Clutch Disc Alignment tool (09301-00210 on 4-cylinder; 09301-00220 on V6), center clutch disc on flywheel. Install and alternately tighten clutch cover bolts in sequence to specification. See Fig. 12 . See TORQUE SPECIFICATIONS . 4. Apply molybdenum disulfide grease to clutch release fork-to-pivot stud contact surfaces, hub on clutch release bearing and clutch disc splines. Install clutch release fork and clutch release bearing on transaxle (if removed). 5. Using transmission jack, position transaxle to engine. Position rear end plate, manifold support and right side stiffener plate. Install, but do not tighten 8 bolts. Install subframe suspension member and tighten bolts and nuts to specification. Install fender liners. Install power steering return pipe bracket. 6. Remove engine support. Install and tighten engine rear side mounting nuts and install hole plug. Install and tighten left engine mounting insulator and bracket bolts, nuts and hole plugs. Install and tighten engine front side mounting Silver and Green bolts. Tighten 8 rear end plate, manifold support and right side stiffener plate bolts to specification. See TORQUE SPECIFICATIONS . 7. To complete installation, reverse removal procedure. Install NEW exhaust pipe gaskets and exhaust pipe-to-exhaust manifold flange nuts. Line up transaxle input shaft and temporarily tighten transaxle mounting bolts. Ensure transaxle-to-engine mounting surfaces are flush before tightening mounting bolts to specification. 8. Tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS . Fill transaxle with 75W-90 gear oil with API GL-4 or GL-5 rating. Align front wheels.
CLUTCH PEDAL HEIGHT 1. Measure clutch pedal height from highest point of clutch pedal pad to floor panel. See Fig. 1 . Ensure clutch pedal height is within specification. See CLUTCH PEDAL HEIGHT SPECIFICATIONS table. 2. If clutch pedal height adjustment is required, loosen lock nut and rotate bolt at clutch pedal height adjustment point until correct clutch pedal height is obtained. See Fig. 1 . Check clutch pedal free play and push rod play. See CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY .
CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY 1. To check clutch pedal free play, push clutch pedal downward until beginning of clutch resistance is felt. See Fig. 2 . Note distance of clutch pedal movement. 2. Clutch pedal free play should be .039-0.197" (1.00-5.00 mm) on MR2, Celica and Corolla. On Camry, Solara, ECHO, RAV4, Tacoma and Tundra models, clutch pedal free play should be .197-0.591" (5.00-15.01 mm). If clutch pedal free play adjustment is required, loosen lock nut on push rod at master cylinder. See Fig. 1 . Rotate push rod to obtain correct pedal free play. Tighten lock nut. 3. To check push rod play, slightly push clutch pedal downward until slight resistance is felt (point where push rod just starts to operate clutch master cylinder). Push rod play should be .197-0.59" (5.00-15.00 mm) at top of clutch pedal for Celica, Corolla and MR2 models. Push rod play should be .039-0.197" (1.00-5.00 mm) for Camry, ECHO, RAV4, Solara, Tacoma and Tundra models. 4. If push rod play adjustment is required, loosen lock nut on push rod at master cylinder. Rotate push rod to obtain correct push rod play. Tighten lock nut. Recheck clutch pedal free play and clutch pedal height. Fig. 2: Measuring Clutch Pedal Free Play (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLUTCH PEDAL RELEASE POINT 1. Block wheel and set parking brake. Start engine and allow it to idle. Without depressing clutch pedal, slowly move shift lever into reverse shift slot until gears begin to mesh (gear contact is heard). Gradually depress clutch pedal and measure stroke distance from point gear noise stops to full stroke end position. 2. Distance should be .98" (25.0 mm) or more. If distance is not as specified, check pedal height, push rod play and pedal free play. See CLUTCH PEDAL HEIGHT and CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY. If clutch pedal adjustments are as specified, bleed clutch system. If after bleeding system, distance is still not as specified, inspect clutch cover and disc for excessive wear.
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Saturday, September 4th, 2010 AT 11:40 AM