Toyota Corolla (E120) 2002–2008 Repair Manual / Clutch / Clutch release cylinder assy (mtm) / Overhaul

Toyota Corolla (E120): Overhaul

1. Drain clutch fluid

2. Disconnect clutch release cylinder to flexible hose tube

1. Using sst, disconnect the flexible hose tube.

   Sst 09023–00100

Hint

: use a container to catch the fluid.

3. Remove clutch release cylinder assy

1. Remove the 3 bolts, clutch release cylinder assy and clutch line bracket.

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: 8.4 Nvm (85 Kgf·cm, 74 in.Vlbf)

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 parts 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

1. Install the clutch release cylinder and clutch line bracket with the 2 bolts.

   Torque: 11.8 Nvm (120 Kgf·cm, 9 ft·lbf)

2.  install the flexible hose tube with the bolt.

   Torque: 5.0 Nvm (51 Kgf·cm, 44 in.Vlbf)

9. Connect clutch release cylinder to flexible hose tube

1. Using sst, connect the flexible hose tube.

   Sst 09023–00100
   torque: 15.2 Nvm (155 Kgf·cm, 11 ft·lbf)

10. Bleed clutch pipe line

1.  fill the brake reservoir tank with brake fluid and bleed clutch system.

   Torque: 8.4 Nvm (85 Kgf·cm, 74 in.Vlbf)

11. Check clutch fluid leakage