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42–1

CLUTCH – CLUTCH SYSTEM (MTM)

CLUTCH SYSTEM (MTM)
4203K–01

PROBLEM SYMPTOMS TABLE
HINT: Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area 5. Engine mounting (Loosen) 6. Clutch disc assy (Runout is excessive) 7. Clutch disc assy (Oily) 8. Clutch disc assy (Worn out) 9. Clutch disc torsion rubber (Damaged) 10.Clutch disc assy (Glazed) 11.Diaphragm spring (Out of tip alignment) 1. Clutch Line (Air in line) 2. Master cylinder cup (Damaged) 3. Release cylinder rubber (Damaged) 1. Clutch release bearing assy (Worn, dirty, or damaged) 2. Clutch disc torsion rubber (Damaged) 1. 2. 3. 4. 5. 6. Clutch pedal (Free play out of adjustment) Clutch disc assy (Oily) Clutch disc assy (Worn out) Diaphragm spring (Damaged) Pressure plate (Distortion) Flywheel sub–assy (Distortion) See page – 42–18 42–18 42–18 42–18 42–18 42–18 – 42–10 42–15 42–15 42–18 42–2 42–18 42–18 42–18 42–18 – 42–2 – 42–10 42–15 42–18 42–18 42–18 42–18 42–18 42–18

Clutch grabs/chatters

Clutch pedal spongy

Clutch noisy

Clutch slips

Clutch does not disengage

1. Clutch pedal (Free play out of adjustment) 2. Clutch line (Air in line) 3. Master cylinder cup (Damaged) 4. Release cylinder cup (Damaged) 5. Clutch disc assy (Out of true) 6. Clutch disc assy (Runout of excessive) 7. Clutch disc assy (Lining broken) 8. Clutch disc assy (Dirty or burned) 9. Clutch disc assy (Oily) 10.Clutch disc assy (Lack of spline grease)

2004 COROLLA (RM1037U)

AuthorĂ:

DateĂ:

1498

42–2
CLUTCH – CLUTCH PEDAL SUB–ASSY (MTM)

CLUTCH PEDAL SUB–ASSY (MTM)
4203L–01

ADJUSTMENT
1. (a) INSPECT AND ADJUST CLUTCH PEDAL SUB–ASSY Turn over the floor carpet.

Push Rod Play and Free Play Adjust Point

(b)

(c)

(d)
Pedal Height Adjust Point Push Rod Play

Check that the pedal height is correct. Pedal height from asphalt sheet: 135.8 – 145.8 mm (5.346 – 5.740 in.) Adjust the pedal height. (1) Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. Torque: 24.5 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) Check that the pedal free play and push rod play are correct. (1) Depress the pedal until the clutch resistance begin to be felt. Pedal free play: 5.0 – 15.0 mm (0.197 – 0591 in.) (2) Gently depress the pedal until the resistance begins to increase a little. Push rod play at pedal top: 1.0 – 5.0 mm (0.039 – 0.197 in.)

Pedal Height
D26341

(e)

Pedal Free Play
CL0102

Adjust the pedal free play and push rod play. (1) Loosen the lock nut and turn the push rod until the free play and push rod play are correct. (2) Tighten the lock nut. (3) After adjusting the pedal free play, check the pedal height. (4) Connect the air duct and install the lower finish panel.

2004 COROLLA (RM1037U)

AuthorĂ:

DateĂ:

1499

) or more Release Point Full Stroke End Position CL0512 Check the clutch release point. (f) 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1500 . (3) Without depressing the clutch pedal. S Check push rod play and pedal free play. slowly shift the shift lever into reverse position until the gears contact. S Check pedal height. (1) Pull the parking brake lever and install wheel stopper. S Check the clutch cover assy and disc assy. S Bleed the clutch line.98 in.98 in. (4) 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. perform the following operations. (2) Start the engine and idle the engine. Standard distance: 25 mm (0.) or more (From pedal stroke end position to release point) If the distance is not as specified.42–3 CLUTCH – CLUTCH PEDAL SUB–ASSY (MTM) 25 mm (0.

1 Cushion Clutch Master Cylinder Push Rod Clevis Bush Clutch Pedal Pad Clutch Pedal Sub–assy N⋅m (kgf⋅cm. 9) Clutch Start Switch Assy Connector Clutch Pedal Bush Clutch Pedal No.8 (120.8 (375. ft⋅lbf) : Specified torque z Non–reusable part MP Grease Clutch Pedal Sub–assy D26342 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1501 .42–4 CLUTCH – CLUTCH PEDAL SUB–ASSY (MTM) 4203M–01 COMPONENTS Clutch Master Cylinder Push Rod Clevis w/ Hole Pin 19. 27) Clutch Pedal Spring Clutch Pedal Support Sub–assy Clutch Pedal Bush 11. 14) Clip 36.1 (195.

D26333 6. D26327 4. Remove the 2 nuts. REMOVE INSTRUMENT PANEL SUB–ASSY LOWER (See page 71–10) REMOVE CLUTCH PEDAL SPRING 3. D26343 5. (a) (b) REMOVE CLUTCH PEDAL SUB–ASSY Remove the bolt and nut. (a) (b) (c) REMOVE CLUTCH PEDAL SUPPORT SUB–ASSY w/ Cruise control: Disconnect the clutch switch assy connector.42–5 CLUTCH – CLUTCH PEDAL SUB–ASSY (MTM) 4203N–02 REPLACEMENT 1. (a) REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN Remove the clip and hole pin. Remove the clutch pedal sub–assy from the clutch pedal support. REMOVE CLUTCH PEDAL PAD 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1502 . Disconnect the clutch start switch assy connector. 2. bolt and clutch pedal support assy.

1 cushion from the clutch pedal. MP Grease D26337 11.1 cushion to the clutch pedal. remove the clevis bush from the clutch pedal sub–assy. D26334 8. Install the clevis bush to the clutch pedal. remove the No. (a) INSTALL CLUTCH PEDAL NO. (a) REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH Using a 8 mm hexagon wrench and a hammer. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH Apply MP grease to inside of a new clevis bush. D26336 10. D26335 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1503 . install the No.42–6 CLUTCH – CLUTCH PEDAL SUB–ASSY (MTM) 7. (a) REMOVE CLUTCH PEDAL BUSH Remove the 2 bushes from the clutch pedal.1 CUSHION Using needle–nose pliers. (a) REMOVE CLUTCH PEDAL NO. (a) (b) HINT: Install the clevis bush from the right side of the vehicle.1 CUSHION Using needle–nose pliers. D26335 9.

1 N⋅m (195 kgf⋅cm. D26333 15. w/ Cruise control: Connect the clutch switch assy connector. D26343 16.42–7 CLUTCH – CLUTCH PEDAL SUB–ASSY (MTM) 12. Install the 2 bushes to the clutch pedal. (a) (b) INSTALL CLUTCH PEDAL BUSH Apply MP grease to both side of 2 new bushes. 27 ft⋅lbf) HINT: Install the bolt from the right side of the vehicle. (c) Install the clip to the hole pin. 9 ft⋅lbf) Connect the clutch start switch assy connector. 14 ft⋅lbf) Nut: 11. AuthorĂ: DateĂ: 1504 . Connect the clevis to the clutch pedal sub–assy with the hole pin. (a) (b) INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN Apply MP grease to the contact surface of the hole pin and clevis bush. INSTALL CLUTCH PEDAL PAD 14. (a) INSTALL CLUTCH PEDAL SUB–ASSY Install the clutch pedal sub–assy to the clutch pedal support with the bolt and nut.8 N⋅m (375 kgf⋅cm. MP Grease D26334 13. (a) (b) (c) INSTALL CLUTCH PEDAL SUPPORT SUB–ASSY Install the clutch pedal support to the vehicle with the 2 nuts and bolt. Torque: 36.8 N⋅m (120 kgf⋅cm. MP Grease 2004 COROLLA (RM1037U) D26306 HINT: Install the hole pin from the right side of the vehicle. Torque: Bolt: 19.

INSTALL CLUTCH PEDAL SPRING INSTALL INSTRUMENT PANEL SUB–ASSY LOWER INSPECT SRS WARNING LIGHT (See page 05–424) INSPECT AND ADJUST CLUTCH PEDAL SUB–ASSY (See page 42–2) 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1505 . 18.42–8 CLUTCH – CLUTCH PEDAL SUB–ASSY (MTM) 17. 19. 20.

8 (120. ft⋅lbf) : Specified torque z Non–reusable part Lithium soap base glycol grease MP grease D11544 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1506 . 11) Clevis Clip Stop Plate Push Rod Piston Spring Master Cylinder Body 11. 9) Snap Ring Clutch Pedal Spring N⋅m (kgf⋅cm. 18) 15.42–9 CLUTCH – CLUTCH MASTER CYLINDER ASSY (MTM) CLUTCH MASTER CYLINDER ASSY (MTM) 4203O–01 COMPONENTS Clutch Master Cylinder Push Rod Clevis w/ Hole Pin Clutch Reservoir Tube Clip Boot Inlet Union z Grommet Slotted Spring Pin Lock Nut 24.5 (245.2 (155.

REMOVE CLUTCH PEDAL SPRING 7. 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1507 . 2. D26327 8. (a) DISCONNECT CLUTCH RESERVOIR TUBE Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder assy. SST 09023–00100 HINT: Use a container to catch the fluid. DRAIN CLUTCH FLUID REMOVE BRAKE MASTER CYLINDER SUB–ASSY (See page 32–13) REMOVE BRAKE BOOSTER ASSY (See page 32–20) 4. (a) SST DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE Using SST. disconnect the flexible hose tube. HINT: Use a container to catch the fluid. 3. (a) REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN Remove the clip and hole pin. D07707 6. (a) REMOVE CLUTCH MASTER CYLINDER ASSY Remove the 2 nuts and clutch master cylinder assy.42–10 CLUTCH – CLUTCH MASTER CYLINDER ASSY (MTM) 4203P–02 OVERHAUL 1. D07708 5.

(b) Install the piston with spring into the cylinder. INSTALL CLUTCH MASTER CYLINDER KIT (a) Coat parts with lithium soap base glycol grease. using snap ring pliers. (a) (b) (c) (d) (e) D07728 REMOVE CLUTCH MASTER CYLINDER KIT Using a pin punch and a hammer. NOTICE: Be careful not to damage the inside of the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (g) Remove the push rod from the cylinder body. NOTICE: The piston may pop up out of the cylinder body. (f) CL0533 While pushing the push rod.42–11 CLUTCH – CLUTCH MASTER CYLINDER ASSY (MTM) 9. remove the snap ring. Install the inlet union and a new grommet. 10. Remove the lock nut from the push rod. Remove the inlet union and grommet. CL0528 (e) (f) (g) (h) (i) CL0533 While pushing the push rod. using snap ring pliers. Temporarily install the clevis with the lock nut to the push rod. (c) Install the stop plate to the push rod. (h) Remove the stop plate from the push rod. Therefore. (d) Install the push rod to the cylinder body. as shown in the illustration. slowly remove the push rod from the cylinder body. (i) Remove the piston with spring from the cylinder. Loosen the lock nut. drive out the slotted spring pin. install the snap ring. 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1508 . Install the lock nut to the push rod. Install the boot to the cylinder body. Remove the boot from the cylinder body. and remove the clevis.

INSTALL CLUTCH PEDAL SPRING 14. connect the flexible hose tube.42–12 CLUTCH – CLUTCH MASTER CYLINDER ASSY (MTM) Protrusion 1. Torque: 11. MP Grease D26306 HINT: Install the hole pin from the right side of the vehicle.059 – 0. drive in the slotted spring pin. (a) SST CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE Using SST. 9 ft⋅lbf) 12. SST 09023–00100 Torque: 15. White Mark D07708 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1509 .5 – 3. 13. (a) CONNECT CLUTCH RESERVOIR TUBE Connect the clutch reservoir tube with the clip to the clutch master cylinder assy. NOTICE: Facing the white mark upward. (c) Install the clip to the hole pin. D07719 11.8 N⋅m (120 kgf⋅cm. 11 ft⋅lbf) D07707 15.5 mm (0. Connect the clevis to the clutch pedal sub–assy with the hole pin.2 N⋅m (155 kgf⋅cm. (a) (b) INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN Apply MP grease to the contact surface of the hole pin and clevis bush.) (j) Using a pin punch and a hammer. (a) INSTALL CLUTCH MASTER CYLINDER ASSY Install the clutch master cylinder assy with the 2 nuts.138 in.

Torque: 8. 18.42–13 CLUTCH – CLUTCH MASTER CYLINDER ASSY (MTM) 16. 21. 24. 17. (a) 20. 22. 23. INSTALL BRAKE BOOSTER ASSY (See page 32–20) INSTALL BRAKE MASTER CYLINDER SUB–ASSY (See page 32–13) BLEED BRAKE LINE (See page 32–4) BLEED CLUTCH PIPE LINE Fill the brake reservoir tank with clutch fluid and bleed clutch system.⋅lbf) CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32–6) INSPECT AND ADJUST CLUTCH PEDAL SUB–ASSY (See page 42–2) CHECK BRAKE FLUID LEAKAGE CHECK CLUTCH FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1510 . 73 in.4 N⋅m (85 kgf⋅cm. 19.

11) Flexible Hose Tube 11.42–14 CLUTCH – CLUTCH RELEASE CYLINDER ASSY (MTM) CLUTCH RELEASE CYLINDER ASSY (MTM) 4203Q–01 COMPONENTS 5.2 (155.⋅lbf) Release Cylinder Bleeder Plug Cap Release Cylinder Body Piston Push Rod z Spring Boot N⋅m (kgf⋅cm. 9) Flexible Hose Tube Bracket Bleeder Plug 8. ft⋅lbf) : Specified torque z Non–reusable part Lithium soap base glycol grease D11545 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1511 .⋅lbf) 15.8 (120. 44 in.4 (85.0 (51. 74 in.

disconnect the flexible hose tube. (b) Remove the push rod from the cylinder body. REMOVE CLUTCH RELEASE CYLINDER KIT (a) Remove the boot from the cylinder body. (e) Remove the bleeder plug cap from the bleeder plug. 5. (c) Remove the piston from the cylinder body. SST D26809 3. D26810 4. 74 in.42–15 CLUTCH – CLUTCH RELEASE CYLINDER ASSY (MTM) 4203R–01 OVERHAUL 1. (a) REMOVE CLUTCH RELEASE CYLINDER ASSY Remove the 3 bolts. INSTALL RELEASE CYLINDER BLEEDER PLUG Torque: 8. NOTICE: Be careful not to damage the inside of the cylinder body. DRAIN CLUTCH FLUID 2. REMOVE RELEASE CYLINDER BLEEDER PLUG 6. clutch release cylinder assy and clutch line bracket.4 N⋅m (85 kgf⋅cm. (a) DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE Using SST. (d) Remove the spring from the cylinder body. SST 09023–00100 HINT: Use a container to catch the fluid.⋅lbf) 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1512 .

44 in. (f) Install the boot to the cylinder body. 11 ft⋅lbf) SST D26809 10.⋅lbf) CHECK CLUTCH FLUID LEAKAGE 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1513 . (a) 11.2 N⋅m (155 kgf⋅cm. NOTICE: Be careful not to damage the inside of the cylinder body. (e) Install the push rod to the cylinder body. Torque: 11.0 N⋅m (51 kgf⋅cm. CL0672 8. 9 ft⋅lbf) Install the flexible hose tube with the bolt. (a) (b) INSTALL CLUTCH RELEASE CYLINDER KIT Install the bleeder plug cap to the bleeder plug. SST 09023–00100 Torque: 15. Install a new spring to the cylinder body. (a) (b) INSTALL CLUTCH RELEASE CYLINDER ASSY Install the clutch release cylinder and clutch line bracket with the 2 bolts. BLEED CLUTCH PIPE LINE Fill the brake reservoir tank with brake fluid and bleed clutch system. Torque: 8. (d) Install the piston to the cylinder body.4 N⋅m (85 kgf⋅cm.8 N⋅m (120 kgf⋅cm. as shown in the illustration. 74 in.⋅lbf) D26810 9.42–16 CLUTCH – CLUTCH RELEASE CYLINDER ASSY (MTM) 7. connect the flexible hose tube. Torque: 5. (a) CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE Using SST. (c) Coat parts with lithium soap base glycol grease.

8 (375. 14) Clutch Release x6 Fork Sub–assy Clutch Release Bearing Assy Release Bearing Hub Clip Flywheel Sub–assy Clutch Cover Assy Release Fork Support 36.42–17 CLUTCH – CLUTCH UNIT (MTM) CLUTCH UNIT (MTM) 4203S–01 COMPONENTS Clutch Disc Assy 19.1 (195. ft⋅lbf) : Specified torque Clutch spline grease Release hub grease D26321 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1514 . 27) Clutch Release Fork Boot N⋅m (kgf⋅cm.

(a) 5. (a) INSPECT CLUTCH DISC ASSY Using vernier calipers. NOTICE: Take care not to insert the clutch disc assy in the wrong direction. REMOVE CLUTCH RELEASE BEARING ASSY Remove the clutch release bearing assy from the clutch release fork. REMOVE CLUTCH DISC ASSY NOTICE: Keep the lining part of the clutch disc assy. 9. REMOVE RELEASE FORK SUPPORT Remove the release fork support from the transaxle assy. REMOVE RELEASE BEARING HUB CLIP REMOVE CLUTCH RELEASE FORK BOOT 7. REMOVE MANUAL TRANSAXLE ASSY (See page 41–17) 2. (a) REMOVE CLUTCH RELEASE FORK SUB–ASSY Remove the clutch release fork with clutch release bearing from the transaxle assy. Matchmarks D25280 8. (a) 4. (b) Loosen each set bolt one turn at a time until spring tension is released. replace the clutch disc assy.42–18 CLUTCH – CLUTCH UNIT (MTM) 4203T–01 OVERHAUL 1.3 mm (0. Q01056 3. Maximum rivet depth: 0. 6. (c) Remove the 6 bolts. (b) Install the clutch disc assy to the transaxle assy.012 in. the pressure plate and surface of the flywheel sub–assy away from oil and foreign attachment. and pull off the clutch cover assy. C62956 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1515 .) If necessary. (a) C62955 REMOVE CLUTCH COVER ASSY Align the matchmarks on the clutch cover assy with the one on the flywheel sub–assy. measure the rivet head depth. NOTICE: Do not drop the clutch disc assy.

replace the flywheel sub–assy.0 mm (0. (a) Flywheel Side INSTALL CLUTCH DISC ASSY Insert SST in the clutch disc assy.) B (Width): 6. replace the release bearing assy. replace the clutch disc assy.236 in. D26338 A B 10.) If necessary. check the clutch disc assy runout. Q01060 13. inspect the flywheel sub–assy runout.8 mm (0.031 in. SST 09301–00210 NOTICE: Take care not to insert clutch disc assy in the wrong direction. replace clutch cover assy. (a) INSPECT CLUTCH RELEASE BEARING ASSY Turn the release bearing by hand while applying force in the axial direction.004 in. Minimum runout: 0. (a) INSPECT CLUTCH COVER ASSY Using vernier calipers.42–19 CLUTCH – CLUTCH UNIT (MTM) (c) Transaxle Side Using a dial indicator. inspect the diaphragm spring for depth and width of wear. Maximum: A (Depth): 0.1 mm (0.) If necessary. D25281 C57466 11. (a) INSPECT FLYWHEEL SUB–ASSY Using a dial indicator. then insert them in the flywheel sub–assy. C62958 12.) If necessary.5 mm (0. D26339 SST 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1516 . Maximum runout: 0. If necessary.020 in. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.

CLUTCH SPLINE GREASE or equivalent (b) Install the bearing to the release fork. Maximum non–alignment: 0. (b) Release hub grease D27398 19. (a) (b) 5 2 Matchmarks D26323 INSTALL CLUTCH COVER ASSY Align the matchmarks on the clutch cover assy and flywheel sub–assy. adjust the diaphragm spring tip alignment. Sealant: Part No.) If alignment is not as specified. 27 ft⋅lbf) INSTALL RELEASE BEARING HUB CLIP 18. after checking that the disc is in the center. tighten the 6 bolts. Torque: 36. using SST. 08887–01706. 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1517 .42–20 CLUTCH – CLUTCH UNIT (MTM) SST 3 6 7 1 (Temporally). (a) INSTALL CLUTCH RELEASE FORK SUB–ASSY Apply release hub grease to the release fork and release bearing assy contact. tighten the bolts at a time evenly.5 mm (0. tighten the bolts. INSTALL RELEASE FORK SUPPORT Install the release fork support to the transaxle assy. move the folk forward and backward to check that the release bearing slides smoothly. NOTICE: After the installation. Following the procedures shown in the illustration. Sealant: Part No. in the order starting the bolt locating near the knock pin on the top. HINT: S S SST 15.1 N⋅m (195 kgf⋅cm. 14 ft⋅lbf) Following the order in the illustration. SST 09333–00013 D00205 16. (a) 17. Move SST up and down. (a) INSTALL CLUTCH RELEASE BEARING ASSY Apply the clutch spline grease to the input shaft spline. and then install them to the transaxle assy. (a) INSPECT AND ADJUST CLUTCH COVER ASSY Using a dial indicator with roller instrument. right and left lightly. 08887–01806. 4 14. RELEASE HUB GREASE or equivalent Install the release fork to the release bearing assy. release fork and push rod contact and release fork pivot points. Torque: 19.8 N⋅m (375 kgf⋅cm. check the diaphragm spring tip alignment.020 in.

42–21 CLUTCH – CLUTCH UNIT (MTM) 20. INSTALL CLUTCH RELEASE FORK BOOT INSTALL MANUAL TRANSAXLE ASSY (See page 41–17) 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1518 . 21.

replace the clutch start switch assy.42–22 CLUTCH – CLUTCH START SWITCH ASSY (MTM) CLUTCH START SWITCH ASSY (MTM) 42028–02 ON–VEHICLE INSPECTION 1. (a) CHECK CLUTCH START SYSTEM Check that the engine does not start when the clutch pedal is released. If necessary. (b) Check that the engine starts when the clutch pedal is fully depressed. Clutch Start Switch Assy D26340 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1519 .

) D11485 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1520 . (a) INSPECT CLUTCH START SWITCH ASSY Check the continuity between the terminals when the switch is ON and OFF.0 " 0.5 mm (0.020 in.315 " 0.42–23 CLUTCH – CLUTCH START SWITCH ASSY (MTM) 42029–02 INSPECTION 1. Switch position ON (pushed) OFF (free) Condition Continuity No continuity 8.

INSPECT CLUTCH START SWITCH ASSY (See page 42–22) 2004 COROLLA (RM1037U) AuthorĂ: DateĂ: 1521 . INSTALL CLUTCH START SWITCH ASSY Install the clutch start switch assy with the nut. (a) (b) 2. Torque: 15. 12 ft⋅lbf) Connect the clutch start switch assy connector. REMOVE CLUTCH START SWITCH ASSY Disconnect the clutch start switch assy connector.68 N⋅m (160 kgf⋅cm. (a) (b) 3. Remove the nut and clutch start switch assy from the clutch pedal support.42–24 CLUTCH – CLUTCH START SWITCH ASSY (MTM) 4203U–01 REPLACEMENT 1.