Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - CLUTCH
CLUTCH MASTER CYLINDER (for RHD) - INSTALLATION
| 1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY |
Install a new gasket to the master cylinder.
Apply MP grease to the contact surface of the clevis and clutch pedal.
Connect the clutch pedal to the clevis, and then install the master cylinder with the 2 nuts.
- Torque:
- 12 N*m{ 120 kgf*cm, 9 ft.*lbf}
Tighten the clutch pedal support bolt.
- Torque:
- 18 N*m{ 184 kgf*cm, 13 ft.*lbf}
| 2. CONNECT CLUTCH RESERVOIR TUBE |
Connect the clutch reservoir tube with a new clip.
| 3. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE |
Using a union nut wrench, connect the tube.
- Torque:
- 15 N*m{ 155 kgf*cm, 11 ft.*lbf}
- NOTICE:
- Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench ().
| 4. FILL RESERVOIR WITH BRAKE FLUID |
Fill the reservoir with brake fluid.
- Brake Fluid:
- SAE J1703 or FMVSS No. 116 DOT 3
| 5. BLEED CLUTCH LINE |
Remove the release cylinder bleeder plug cap.
Connect a vinyl tube to the bleeder plug.
Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.
When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
Repeat the previous 2 steps until all the air in the fluid is completely bled.
Tighten the bleeder plug.
- Torque:
- 11 N*m{ 110 kgf*cm, 8 ft.*lbf}
Install the bleeder plug cap.
Check that all the air has been bled from the clutch line.
| 6. CHECK FLUID LEVEL IN RESERVOIR |
Check the fluid level.
If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.
- Brake fluid:
- SAE J1703 or FMVSS No. 116 DOT 3
| 7. INSPECT FOR CLUTCH FLUID LEAK |
| 8. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY |
Check that the clutch pedal height is correct.
- Standard Clutch Pedal Height from Tibia Pad:
- 164.8 to 174.8 mm (6.49 to 6.88 in.)
Adjust the clutch pedal height.
Loosen the lock nut and turn the stopper bolt or clutch switch until the height is correct. Tighten the lock nut.
- Torque:
- 16 N*m{ 160 kgf*cm, 12 ft.*lbf}
Check that the clutch pedal free play and push rod play are correct.
- HINT:
- Pay close attention to the change in resistance to distinguish between pedal free play and push rod play while performing the inspection.
Depress the clutch pedal until the clutch resistance begins to be felt.
- Standard Clutch Pedal Free Play:
- 5.0 to 15.0 mm (0.197 to 0.591 in.)
Gently depress the clutch pedal until the resistance begins to increase a little.
- Standard Push Rod Play at Pedal Top:
- 1.0 to 5.0 mm (0.0394 to 0.197 in.)
Adjust the clutch pedal free play and push rod play.
- HINT:
- The push rod play can be adjusted by changing the length of the push rod. Pedal free play changes together with push rod play.
Loosen the lock nut and turn the push rod until the clutch pedal free play and push rod play are correct.
- NOTICE:
- If pedal free play and push rod play are not within the standard range even after adjustment, inspect the related parts.
Tighten the lock nut.
- Torque:
- 12 N*m{ 120 kgf*cm, 9 ft.*lbf}
After adjusting the clutch pedal free play and push rod play, check the clutch pedal height.
- Standard Clutch Pedal Height from Tibia Pad:
- 164.8 to 174.8 mm (6.49 to 6.88 in.)
Check the clutch release point.
Pull the parking brake lever and chock the wheels.
Start the engine and allow it to idle.
Without depressing the clutch pedal, slowly move the shift lever to R until the gears engage.
Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.
- Standard Distance from Pedal Stroke End Position to Release Point:
- 20 mm (0.787 in.) or more
If the distance is not as specified, perform the following operations: