Toyota Corolla (E120): Overhaul
1. Remove manual transaxle assy
2. Remove clutch release fork sub–assy
- Remove the clutch release fork with clutch release bearing from the transaxle assy.
3. Remove clutch release bearing assy
- remove the clutch release bearing assy from the clutch release fork.
4. Remove release fork support
- remove the release fork support from the transaxle assy.
5. Remove release bearing hub clip
6. Remove clutch release fork boot
7. Remove clutch cover assy
- Align the matchmarks on the clutch cover assy with the one on the flywheel sub–assy.
- loosen each set bolt one turn at a time until spring tension is released.
- remove the 6 bolts, and pull off the clutch cover assy.
Notice
: do not drop the clutch disc assy.
8. Remove clutch disc assy
Notice
: keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub–assy away from oil and foreign attachment.
9. Inspect clutch disc assy
- Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 Mm (0.012 In.)
If necessary, replace the clutch disc assy.
- install the clutch disc assy to the transaxle assy.
Notice
: take care not to insert the clutch disc assy in the wrong direction.
- Using a dial indicator, check the clutch disc assy runout.
Minimum runout: 0.8 Mm (0.031 In.)
If necessary, replace the clutch disc assy.
10. Inspect clutch cover assy
- Using vernier calipers, inspect the diaphragm spring for
depth and width of wear.
Maximum:
a (depth): 0.5 Mm (0.020 In.) B (width): 6.0 Mm (0.236 In.)
If necessary, replace clutch cover assy.
11. Inspect flywheel sub–assy
- Using a dial indicator, inspect the flywheel sub–assy runout.
Maximum runout: 0.1 Mm (0.004 In.)
If necessary, replace the flywheel sub–assy.
12. Inspect clutch release bearing assy
- Turn the release bearing by hand while applying force in the axial direction.
Hint
: the bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the release bearing assy.
13. Install clutch disc assy
- Insert sst in the clutch disc assy, then insert them in the
flywheel sub–assy.
Sst 09301–00210
Notice
: take care not to insert clutch disc assy in the wrong direction.
14. Install clutch cover assy
- Align the matchmarks on the clutch cover assy and flywheel sub–assy.
- following the procedures shown in the illustration, tighten
the 6 bolts, in the order starting the bolt locating near the
knock pin on the top.
Torque: 19.1 Nvm (195 Kgf·cm, 14 ft·lbf)
H
int
:
- following the order in the illustration, tighten the bolts at a time evenly.
- Move sst up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.
15. Inspect and adjust clutch cover assy
- Using a dial indicator with roller instrument, check the diaphragm
spring tip alignment.
Maximum non–alignment: 0.5 Mm (0.020 In.)
If alignment is not as specified, using sst, adjust the diaphragm spring tip alignment.
Sst 09333–00013
16. Install release fork support
- install the release fork support to the transaxle assy.
Torque: 36.8 Nvm (375 Kgf·cm, 27 ft·lbf)
17. Install release bearing hub clip
18. Install clutch release fork sub–assy
- Apply release hub grease to the release fork and release
bearing assy contact, release fork and push rod contact
and release fork pivot points.
Sealant:
part no. 08887–01806, Release hub grease or equivalent - install the release fork to the release bearing assy.
19. Install clutch release bearing assy
- apply the clutch spline grease to the input shaft spline.
Sealant: part no. 08887–01706, Clutch spline grease or equivalent
- install the bearing to the release fork, and then install them to the transaxle assy.
Notice
: after the installation, move the folk forward and backward to check that the release bearing slides smoothly.
20. Install clutch release fork boot
21. Install manual transaxle assy
Other materials:
Correct driving posture
1 Adjust the angle of the seatback so that you are sitting straight up and so
that you do not have to lean forward to steer.
2 Adjust the seat so that you can depress the pedals fully and so that your arms
bend slightly at the elbow when gripping the steering wheel.
3 Lock the head restraint ...
Cigarette lighter assy
Replacement
Hint: components:
1. Remove floor shift shift lever knob sub–assy (m/t transaxle)
2. Remove console panel upper
3. Remove cigarette lighter cover
Disengage the 2 claws and remove the cigarette lighter
cover.
4. Remove cigarette lighter assy
Turn the socket in ...
Driving support system
information display
■ Driving support system
information
Select to display the operational
status of the following systems:
LTA (Lane Tracing Assist)
LDA (Lane Departure Alertl)
Dynamic radar cruise control
■ Navigation system-linked
display (if equipped)
Select to display the following
navigation system-linke ...