Toyota Camry 2007-2009 Service Manual - Clutch
CLUTCH – CLUTCH SYSTEM
CLUTCH SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem.
The numbers indicate the ranked order of probability of each
of the possible causes. Check each part in order. Replace
parts as necessary.
CLUTCH SYSTEM
Symptom Suspected area See page
1. Engine mounting (Loosen) -
2. Clutch disc (Runout is excessive) CL-32
3. Clutch disc (Oily) CL-32
Clutch grabs/chatters
Clutch pedal is spongy
Clutch is noisy 1. Release bearing (Worn, dirty, or damaged) CL-33
Clutch slips
Clutch does not disengage
4. Clutch disc (Worn out) CL-32
5. Clutch disc torsion rubber (Damaged) CL-32
6. Clutch disc (Glazed) CL-32
7. Diaphragm spring (Out of tip alignment) CL-32
1. Clutch Line (Air in line) CL-25
2. Master cylinder cup (Damaged) CL-15
3. Release cylinder rubber (Damaged) CL-24
1. Clutch pedal (Free play is out of adjustment) CL-4
2. Clutch disc (Oily) CL-32
3. Clutch disc (Worn out) CL-32
4. Diaphragm spring (Damaged) CL-33
5. Pressure plate (Distortion) CL-32
6. Flywheel (Distortion) CL-33
1. Clutch pedal (Free play is out of adjustment) CL-4
2. Clutch line (Air in line) CL-25
3. Master cylinder cup (Damaged) CL-15
4. Release cylinder cup (Damaged) CL-24
5. Clutch disc (Out of true) CL-32
6. Clutch disc (Runout is excessive) CL-32
7. Clutch disc (Lining broken) CL-32
8. Clutch disc (Dirty or burned) CL-32
9. Clutch disc (Oily) CL-32
10. Clutch disc (Lack of spline grease) CL-32
CL–1
CL
CL–2
TRANSMISSIONCLUTCH
CLUTCH PEDAL
COMPONENTS
for TMC Made:
CLUTCH – CLUTCH PEDAL
CL
<E>
<E>
COMBINATION METER ASSEMBLY
INSTRUMENT CLUSTER FINISH PANEL
NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY
<E>
with Smart Key System:
<E>
LOWER INSTRUMENT PANEL
FINISH PANEL
without Smart Key System:
LOWER INSTRUMENT PANEL
FINISH PANEL
COWL SIDE TRIM SUB-ASSEMBLY LH
COWL SIDE TRIM CLIP
LOWER INSTRUMENT PANEL FINISH PANEL LH
FRONT DOOR SCUFF PLATE LH
<B>
<A>
C138372E01
for TMMK Made:
CLUTCH – CLUTCH PEDAL
CL–3
<R> <R>
<R>
COMBINATION METER ASSEMBLY
INSTRUMENT CLUSTER FINISH PANEL
NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY
<R>
with Smart Key System:
CL
LOWER INSTRUMENT PANEL
FINISH PANEL
without Smart Key System:
LOWER INSTRUMENT PANEL
FINISH PANEL
COWL SIDE TRIM SUB-ASSEMBLY LH
COWL SIDE TRIM CLIP
LOWER INSTRUMENT PANEL FINISH PANEL LH
FRONT DOOR SCUFF PLATE LH
<O> or <P>
<N>
C138372E02
CL
CL–4
CLUTCH – CLUTCH PEDAL
PUSH ROD CLEVIS
19 (195, 14)
37 (375, 27)
CLUTCH PEDAL
SPRING HOLDER
PEDAL SHAFT
CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
CLUTCH PEDAL
BUSHING
CLUTCH MASTER CYLINDER
PUSH ROD CLEVIS PIN
CLUTCH PEDAL
SHAFT COLLAR
12 (120, 9)
TORSION SPRING
NO. 1 CLUTCH PEDAL CUSHION
CLUTCH PEDAL BUSHING
CLIP
PEDAL WITH
HOOK SPRING
CLUTCH PEDAL
TURNOVER
BUSHING
CLUTCH MASTER
CYLINDER PUSH ROD
CLEVIS BUSHING
N*m (kgf*cm, ft.*lbf)
CLUTCH PEDAL SUB-ASSEMBLY
: Specified torque
NO. 1 CLUTCH
PEDAL CUSHION
Non-reusable part
CLUTCH PEDAL PAD
Apply MP grease
C132965E01
Pedal Height
Adjustment Point
Push Rod Play
and Free Play
Adjustment Point
Pedal Height
CLUTCH – CLUTCH PEDAL
ON-VEHICLE INSPECTION
1. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
(a) Turn back the floor carpet.
(b) Check the pedal height.
Pedal height from asphalt sheet:
148.0 to 158.0 mm (5.8268 to 6.2205 in.)
If necessary, adjust the pedal height.
(c) Adjust the pedal height.
(1) Loosen the lock nut and turn the clutch switch
until the height is correct. Tighten the lock nut.
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
CL–5
CL
Pedal Free Play
Full Stroke
End
Position
Push Rod Play
25 mm (0.98 in.) or more
Release Point
C138378E01
C102627E01
2. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH
ROD PLAY
(a) Check that the pedal free play and push rod play are
correct.
(1) Depress the pedal until clutch resistance is felt.
Pedal free play:
5.0 to 15.0 mm (0.197 to 0.591 in.)
(2) Gently depress the pedal until the resistance
begins to increase a little.
Push rod play at pedal top:
1.0 to 5.0 mm (0.039 to 0.197 in.)
(b) Adjust the pedal free play and push rod play.
(1) Loosen the lock nut and turn the push rod until
the free play and push rod play are correct.
(2) Tighten the lock nut.
Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf)
(3) After adjusting the pedal free play, check the
pedal height.
3. INSPECT CLUTCH RELEASE POINT
(a) Check the clutch release point.
(1) Pull the parking brake lever and install the
wheel stopper .
(2) Start and idle the engine.
(3) Without depressing the clutch pedal, slowly
move the shift lever to the reverse position until
the gears are engaged.
CL00512E07
CL
CL–6
CLUTCH – CLUTCH PEDAL
(4) Gradually depress the clutch pedal and
measure the stroke distance from the point that
the gear noise stops (release point) to the full
stroke end position.
Standard distance:
25 mm (0.98 in.) or more (From pedal
stroke end position to release point)
If the distance is not as specified, perform the
following operations:
• Check the pedal height.
• Check push rod play and pedal free play.
• Bleed the clutch line.
• Check the clutch cover assembly and disc
assembly.
CLUTCH – CLUTCH PEDAL
REMOVAL
1. PRECAUTION
See page IP-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE FRONT DOOR SCUFF PLA TE LH (See p age
IR-24)
4. REMOVE COWL SIDE TRIM SUB-ASSEMBL Y LH (See
page IR-25)
5. REMOVE LOWER INSTRUMENT PANEL FINISH
PANEL LH (for TMC Made) (See page IP-20)
6. REMOVE LOWER INSTRUMENT PANEL FINISH
PANEL LH (for TMMK Made) (See page IP-21)
7. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-22)
8. REMOVE LOWER INSTRUMENT PANEL FINISH
PANEL (w/o Smart Key System) (See page IP-22)
CL–7
CL
9. REMOVE LOWER INSTRUMENT PANEL FINISH
PANEL (w/ Smart Key System) (See page IP-22)
10. REMOVE INSTRUMENT CLUSTER FINISH PANEL
(See page IP-22)
11. REMOVE COMBINATION METER ASSEMBLY (for
TMC Made) (See page IP-23)
12. REMOVE COMBINATION METER ASSEMBLY (for
TMMK Made) (See page IP-23)
13. DISCONNECT CONNECTORS
(a) Disconnect the clutch start switch connector.
(b) Disconnect the clutch switch connector (with cruise
control).
14. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS PIN
(a) Remove the clip and pin.
C135429
CL–8
CLUTCH – CLUTCH PEDAL
15. REMOVE CLUTCH PEDAL SUPPORT SUBASSEMBLY
(a) Remove the bolt, 2 nuts and clutch pedal support
assembly.
16. REMOVE TORSION SPRING
(a) While the clutch pedal is fully depressed, remove
the torsion spring.
CL
C132956
C135394
17. REMOVE PEDAL WITH HOOK SPRING
(a) Remove the pedal with hook spring.
18. REMOVE CLUTCH PEDAL SUB-ASSEMBLY
(a) Remove the pedal shaft and nut.
(b) Remove the clutch pedal from the clutch pedal
support.
19. REMOVE CLUTCH PEDAL SPRING HOLDER
(a) Remove the clutch pedal spring holder from the
clutch pedal support.
20. REMOVE CLUTCH PEDAL PAD
(a) Remove the clutch pedal pad from the clutch pedal.
C135422
C135423
21. REMOVE CLUTCH PEDAL BUSHING
(a) Remove the 2 pedal bushings and pedal shaf t collar
from the clutch pedal.
22. REMOVE NO. 1 CLUTCH PEDAL CUSHION
(a) Using needle-nose pliers, remove the 2 No. 1 clutch
pedal cushions from the clutch pedal.
CLUTCH – CLUTCH PEDAL
23. REMOVE CLUTCH PEDAL TURNOVER BUSHING
(a) Remove the turnover bushing from the clutch pedal.
C135424
24. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS BUSHING
(a) Using an 8 mm hexagon wrench and a hammer,
remove the clevis bushing from the clutch pedal.
C135430
CL–9
CL
MP grease
MP grease
C135431E01
C135424E01
INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS BUSHING
(a) Apply MP grease to the inside of a new clevis
bushing.
(b) Install the clevis bushing to the clutch pedal.
HINT:
Install the clevis bushing from the left side of the
vehicle.
2. INSTALL CLUTCH PEDAL TURNOVER BUSHING
(a) Apply MP grease to the inside of the turnover
bushing.
(b) Install the turnover bushing to the clutch pedal.
3. INSTALL NO. 1 CLUTCH PEDAL CUSHION
(a) Using needle-nose pliers, install the 2 No. 1 clutch
pedal cushions to the clutch pedal.
C135423
CL–10
CLUTCH – CLUTCH PEDAL
4. INSTALL CLUTCH PEDAL BUSHING
(a) Apply MP grease to the inner, outer and end
surfaces of 2 new pedal bushings.
(b) Install the clutch pedal shaft collar and 2 pedal
bushings to the clutch pedal.
5. INSTALL CLUTCH PEDAL PAD
(a) Install the clutch pedal pad to the clutch pedal.
CL
MP grease
C135422E01
6. INSTALL CLUTCH PEDAL SPRING HOLDER
(a) Apply MP grease to the inside of a new clutch pedal
spring holder.
(b) Install the clutch pedal spring holder.
MP grease
C135433E01
7. INSTALL CLUTCH PEDAL SUB-ASSEMBLY
(a) Install the clutch pedal 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.
MP grease
MP grease
C135394
8. INSTALL PEDAL WITH HOOK SPRING
(a) Apply MP grease to the sliding portion of the spring.
(b) Install the hook spring.
C132964E01
9. INSTALL TORSION SPRING
(a) Apply MP grease to the sliding portion of the spring.
(b) Install the torsion spring.
C125952E02
CLUTCH – CLUTCH PEDAL
10. INSTALL CLUTCH PEDAL SUPPORT SUBASSEMBLY
(a) Install the clutch pedal support to the vehicle with
the 2 nuts and bolt.
Torque: Bolt
C132956
CL–11
19 N*m (195 kgf*cm, 14 ft.*lbf)
Nut
12 N*m (120 kgf*cm, 9 ft.*lbf)
CL
MP grease
C135428E01
11. INSTALL CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS PIN
(a) Apply MP grease to the contact surface of the pin
and clevis bushing.
(b) Connect the clevis to the clutch pedal with the pin
and a new clip.
HINT:
Install the pin from the left side of the vehicle.
12. CONNECT CONNECTORS
(a) Connect the clutch start switch connector.
(b) Connect the clutch switch connector (with cruise
control).
13. INSTALL COMBINATION METER ASSEMBLY (for
TMC Made) (See page IP-56)
14. INSTALL COMBINATION METER ASSEMBLY (for
TMMK Made) (See page IP-56)
15. INSTALL INSTRUMENT CLUSTER FINISH PANEL
(See page IP-57)
16. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL (w/o Smart Key System) (See page IP-57)
17. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL (w/ Smart Key System) (See page IP-57)
18. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY (See page IP-57)
19. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL LH (for TMC Made) (See page IP-58)
20. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL LH (for TMMK Made) (See page IP-59)
CL–12
CLUTCH – CLUTCH PEDAL
21. INST ALL COWL SIDE TRIM SUB-ASSEMBLY LH (See
page IR-54)
22. INSTALL FRONT DOOR SCUFF PLATE LH (See page
IR-54)
23. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
CL
24. INSPECT AND ADJUST CLUTCH PEDAL SUBASSEMBLY
See page CL-4.
CL–12
TRANSMISSIONCLUTCH
CLUTCH – CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
COMPONENTS
CL
FRONT FENDER TO
COWL SIDE SEAL RH
COWL TOP VENTILATOR
LOUVER SUB-ASSEMBLY
85 (867, 63)
5.0 (51, 44 in.*lbf)
FRONT WIPER ARM AND
BLADE ASSEMBLY RH
7.5 (77, 66 in.*lbf)
20 (204, 15)
FRONT WIPER ARM AND
BLADE ASSEMBLY LH
FRONT FENDER TO
COWL SIDE SEAL LH
COWL TOP PANEL OUTER SUB-ASSEMBLY
N*m (kgf*cm, ft.*lbf)
: Specified torque
WINDSHIELD WIPER
LINK ASSEMBLY
A136912E01
Loading...