Hilux 2015 2018 manual clutch he thong ly hop

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CLUTCH CLUTCH ACCUMULATOR COMPONENTS

ILLUSTRATION

*1
*3

CLUTCH ACCUMULATOR ASSEMBLY
ACCUMULATOR TO FLEXIBLE HOSE TUBE

*2
-

Tightening torque for "Major areas involving
basic vehicle performance such as
moving/turning/stopping" : N*m (kgf*cm,
ft.*lbf)
*

For use with union nut wrench

MASTER CYLINDER TO FLEXIBLE HOSE TUBE
-

N*m (kgf*cm, ft.*lbf) : Specified torque

-

-

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© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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CLUTCH CLUTCH ACCUMULATOR INSTALLATION

PROCEDURE
1.INSTALL CLUTCH ACCUMULATOR ASSEMBLY
a.

31490

Install the clutch accumulator assembly with the 2 nuts.
Torque:
18 N*m (184 kgf*cm, 13 ft.*lbf)

b.

*a

Torque Wrench Fulcrum Length

Using a union nut wrench, connect the master cylinder to flexible hose tube and accumulator to flexible
hose tube.
Torque:
Specified tightening torque : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)
HINT:
·
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION
When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum
length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

2.BLEED AIR FROM CLUTCH PIPE LINE
Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING
3.CHECK FOR CLUTCH FLUID LEAKAGE
HINT:
Check for leaks in the clutch system.

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4.CHECK FLUID LEVEL IN RESERVOIR
Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING
© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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CLUTCH CLUTCH ACCUMULATOR REMOVAL

PROCEDURE
1.REMOVE CLUTCH ACCUMULATOR ASSEMBLY

31490

a.

Using a union nut wrench, disconnect the master cylinder to flexible hose tube and accumulator to flexible
hose tube.
b.

Remove the 2 nuts and clutch accumulator assembly.

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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11/3/17, 7'19 pm

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CLUTCH CLUTCH MASTER CYLINDER(w/ Turn Over) COMPONENTS

ILLUSTRATION

*A

w/o Intelligent Manual Transmission

*B

w/ Master Cylinder Bracket

*1

CLUTCH MASTER CYLINDER ASSEMBLY

*2

CLUTCH MASTER CYLINDER TO FLEXIBLE
HOSE TUBE

*3

CLUTCH RESERVOIR TUBE

*4

MASTER CYLINDER BRACKET

*5
*7

CLEVIS PIN
CLIP

*6
-

GASKET
-

Tightening torque for "Major areas involving
basic vehicle performance such as
moving/turning/stopping" : N*m (kgf*cm,
ft.*lbf)
●

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

*

For use with union nut wrench

MP grease

-

-

ILLUSTRATION
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*A

w/ Intelligent Manual Transmission

*B

*1

CLUTCH MASTER CYLINDER ASSEMBLY

*2

*3

CLUTCH RESERVOIR TUBE

*4

*5
*7

MASTER CYLINDER BRACKET
GASKET

*6
*8

Tightening torque for "Major areas involving
basic vehicle performance such as
moving/turning/stopping" : N*m (kgf*cm,
ft.*lbf)
●

w/ Master Cylinder Bracket
CLUTCH MASTER CYLINDER TO FLEXIBLE
HOSE TUBE
INTELLIGENT MANUAL TRANSMISSION
CONNECTOR
CLEVIS PIN
CLIP

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

*

For use with union nut wrench

MP grease

-

-

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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11/3/17, 7'20 pm

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CLUTCH CLUTCH MASTER CYLINDER(w/ Turn Over) INSTALLATION

CAUTION / NOTICE / HINT
HINT:
·
·

Use the same procedure for RHD and LHD vehicles.
The procedure listed below is for LHD vehicles.

PROCEDURE
1.INSTALL CLUTCH MASTER CYLINDER ASSEMBLY

31410

a.

w/o Master Cylinder Bracket:
i. Install a new gasket and the clutch master cylinder assembly with the 2 nuts.
Torque:
18.4 N*m (188 kgf*cm, 14 ft.*lbf)

b.

w/ Master Cylinder Bracket:
i. Install 2 new gaskets, the master cylinder bracket and the clutch master cylinder assembly with the 2
nuts.
Torque:
18.4 N*m (188 kgf*cm, 14 ft.*lbf)

2.CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>INSTALLATION
3.CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE

31481

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a.

*A

w/o Intelligent Manual Transmission

*B

w/ Intelligent Manual Transmission

*a

Torque Wrench Fulcrum Length

Using a union nut wrench, connect the clutch master cylinder to flexible hose tube.
Torque:
Specified tightening torque : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)
HINT:
·
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION
When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum
length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

4.CONNECT CLUTCH RESERVOIR TUBE
a.

31434

Connect the clutch reservoir tube to the clutch master cylinder assembly, and slide the clip to secure it.
NOTICE:
Connect the clutch reservoir hose so that it is not twisted.

5.CONNECT INTELLIGENT MANUAL TRANSMISSION CONNECTOR (w/ Intelligent Manual
Transmission)
a.

Connect the intelligent manual transmission connector to the clutch master cylinder assembly.

6.BLEED CLUTCH PIPE LINE

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Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING
7.CHECK FOR CLUTCH FLUID LEAKAGE
HINT:
Check for leaks in the clutch system.

8.INSPECT AND ADJUST CLUTCH PEDAL ASSEMBLY

31301

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>ADJUSTMENT
9.CHECK FLUID LEVEL IN RESERVOIR
Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING
© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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CLUTCH CLUTCH MASTER CYLINDER(w/ Turn Over) ON-VEHICLE INSPECTION

PROCEDURE
1.INSPECT CLUTCH MASTER CYLINDER ASSEMBLY (w/ Intelligent Manual
Transmission Switch)

31410

a.

*a

*b

Dry Cell Battery
Clutch Pedal Condition

*c

Released

*d

Depressed

Inspect stroke sensor
i. Connect the positive (+) end of a series of dry cell batteries to terminal 3 (VCCL) and the negative (-)
end to terminal 1 (ECLS), and apply a voltage of 4.5V.
NOTICE:
Do not apply a voltage of 6 V or higher between the terminals.
HINT:
Connect 3 dry cell batteries (1.5 V) in series.
ii.

Measure the voltage between terminals 2 (CLS) and 1 (ECLS) when the clutch pedal is depressed and
released with voltage applied.
Standard Voltage
Tester
Connection

Condition
(Clutch

Pedal)

Standard

2(CLS) 1(ECLS)

Released

0.367 to 0.847
V

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2(CLS) 1(ECLS)

11/3/17, 7'19 pm

Depressed

3.828 to 4.452
V

Standard Voltage (When 5 V Applied)
Tester
Connection

Condition
(Clutch
Pedal)

Standard

2(CLS) 1(ECLS)

Released

0.5 V

2(CLS) 1(ECLS)

Depressed

4.1 V

If the result is not as specified, there may be a malfunction in the stroke sensor.

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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CLUTCH CLUTCH MASTER CYLINDER(w/ Turn Over) REMOVAL

CAUTION / NOTICE / HINT
HINT:
·
·

Use the same procedure for RHD and LHD vehicles.
The procedure listed below is for LHD vehicles.

PROCEDURE
1.DRAIN CLUTCH FLUID
NOTICE:
Wash off clutch fluid immediately if it comes into contact with a painted surface.

2.DISCONNECT INTELLIGENT MANUAL TRANSMISSION CONNECTOR (w/ Intelligent Manual
Transmission)
a.

Disconnect the intelligent manual transmission connector from the clutch master cylinder assembly.

3.DISCONNECT CLUTCH RESERVOIR TUBE

31434

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a.

*A

w/o Intelligent Manual Transmission

*B

w/ Intelligent Manual Transmission

Slide the clip and disconnect the clutch reservoir tube from the clutch master cylinder assembly.
HINT:
Use a container to collect the fluid.

4.DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE

31481

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a.

*A
*B

w/o Intelligent Manual Transmission
w/ Intelligent Manual Transmission

Using a union nut wrench, disconnect the clutch master cylinder to flexible hose tube from the clutch
master cylinder assembly.
HINT:
Use a container to collect the fluid.

5.DISCONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>REMOVAL
6.REMOVE CLUTCH MASTER CYLINDER ASSEMBLY

31410

a.

w/o Master Cylinder Bracket:
i. Remove the 2 nuts, clutch master cylinder assembly and gasket.

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b.

11/3/17, 7'19 pm

w/ Master Cylinder Bracket:
i. Remove the 2 nuts, clutch master cylinder assembly, master cylinder bracket and 2 gaskets.

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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11/3/17, 7'20 pm

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CLUTCH CLUTCH MASTER CYLINDER(w/o Turn Over) COMPONENTS

ILLUSTRATION

*A

w/ Master Cylinder Bracket

-

*1

CLUTCH MASTER CYLINDER ASSEMBLY

*2

CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS

*3

CLUTCH MASTER CYLINDER TO FLEXIBLE
HOSE TUBE

*4

CLUTCH RESERVOIR TUBE

*5

CLEVIS PIN

*6

GASKET

*7

CLIP

*8

MASTER CYLINDER BRACKET

Tightening torque for "Major areas involving
basic vehicle performance such as
moving/turning/stopping" : N*m (kgf*cm,
ft.*lbf)
●

-

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

*

For use with union nut wrench

MP grease

-

-

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.
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11/3/17, 7'20 pm

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CLUTCH CLUTCH MASTER CYLINDER(w/o Turn Over) COMPONENTS

ILLUSTRATION

*A

w/ Master Cylinder Bracket

-

*1

CLUTCH MASTER CYLINDER ASSEMBLY

*2

CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS

*3

CLUTCH MASTER CYLINDER TO FLEXIBLE
HOSE TUBE

*4

CLUTCH RESERVOIR TUBE

*5

CLEVIS PIN

*6

GASKET

*7

CLIP

*8

MASTER CYLINDER BRACKET

Tightening torque for "Major areas involving
basic vehicle performance such as
moving/turning/stopping" : N*m (kgf*cm,

ft.*lbf)
●

-

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

*

For use with union nut wrench

MP grease

-

-

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.
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11/3/17, 7'20 pm

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CLUTCH CLUTCH MASTER CYLINDER(w/o Turn Over) INSTALLATION

CAUTION / NOTICE / HINT
HINT:
·
·

Use the same procedure for RHD and LHD vehicles.
The procedure listed below is for LHD vehicles.

PROCEDURE
1.INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
a.

Install the lock nut and master cylinder push rod clevis to the push rod.
HINT:
Tighten the lock nut to the specified torque when adjusting the clutch pedal.

2.INSTALL CLUTCH MASTER CYLINDER ASSEMBLY

31410

a.

w/o Master cylinder Bracket:
Install a new gasket and the clutch master cylinder assembly with the 2 nuts.
Torque:
18.4 N*m (188 kgf*cm, 14 ft.*lbf)

b.

w/ Master cylinder Bracket:
Install 2 new gaskets, the master cylinder bracket and the clutch master cylinder assembly with the 2 nuts.
Torque:
18.4 N*m (188 kgf*cm, 14 ft.*lbf)

3.CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>INSTALLATION
4.CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE

31481

/>
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11/3/17, 7'20 pm

a.

*a

Torque Wrench Fulcrum Length

Using a union nut wrench, connect the clutch master cylinder to flexible hose tube.
Torque:

Specified tightening torque : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)
HINT:
·
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION
When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum
length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

5.CONNECT CLUTCH RESERVOIR TUBE
a.

31434

Connect the clutch reservoir tube to the clutch master cylinder assembly, and slide the clip to secure it.
NOTICE:
Connect the clutch reservoir hose so that it is not twisted.

6.BLEED AIR FROM CLUTCH PIPE LINE
Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING
7.CHECK FOR CLUTCH FLUID LEAKAGE
HINT:
Check for leaks in the clutch system.

8.INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

31301

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>ADJUSTMENT

9.CHECK FLUID LEVEL IN RESERVOIR
Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING

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