Installation (from 07/2011)

CLUTCH: CLUTCH UNIT (for Hatchback): INSTALLATION

1. INSTALL CLUTCH DISC ASSEMBLY

(a) Insert SST into the clutch disc assembly, and then insert them both into the flywheel sub-assembly.





Text in Illustration





SST : 09301-00210

NOTICE:
Insert clutch disc assembly in the correct direction.

2. INSTALL CLUTCH COVER ASSEMBLY

(a) Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.





Text in Illustration





SST : 09301-00210

(b) Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

Torque : 19 Nm (195 kgf-cm, 14 ft-lbf)

HINT
* Following the order in the illustration, tighten the bolts evenly one at a time.
* Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.

3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

(a) Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.





Maximum non-alignment:

0.5 mm (0.0197 in.)

(b) If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.





SST : 09333-00013

4. INSTALL RELEASE FORK SUPPORT

(a) Install the release fork support to the manual transaxle assembly.

Torque : 37 Nm (375 kgf-cm, 27 ft-lbf)

5. INSTALL CLUTCH RELEASE FORK BOOT

(a) Install the clutch release fork boot to the manual transaxle assembly.

6. INSTALL RELEASE BEARING HUB CLIP

(a) Install the release bearing hub clip to the clutch release bearing assembly.

7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

(a) Apply release hub grease to the contact surfaces of the clutch release fork sub-assembly and clutch release bearing assembly, clutch release fork sub-assembly and No. 1 clutch release cylinder push rod, and clutch release fork sub-assembly and release fork support.





Text in Illustration





Grease:

Toyota Genuine Release Hub Grease or equivalent

(b) Engage the release bearing hub clip and install the clutch release fork sub-assembly to the clutch release bearing assembly.

8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

(a) Apply clutch spline grease to the input shaft spline.





Text in Illustration





Grease:

Toyota Genuine Clutch Spline Grease or equivalent

NOTICE:
Do not apply grease to portion A shown in the illustration.

(b) Install the clutch release bearing assembly with the clutch release fork sub-assembly to the manual transaxle assembly.

NOTICE:
After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

9. INSTALL MANUAL TRANSAXLE ASSEMBLY

Installation (from 07/2011)