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1997 Clutch & V160 PDF
1997 Clutch & V160 PDF
CLUTCH - TROUBLESHOOTING
TROUBLESHOOTING
CL03Y-02
COMPONENTS
REMOVAL
1. 2JZ - GTE:
REMOVE CLUTCH HOUSING COVER LH
Remove the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
2. 2JZ - GTE:
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container to
catch the fluid.
SST 09023-00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. 2JZ - GTE:
REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
4. 2JZ - GE:
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container to
catch the fluid.
SST 09023-00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
Q01125
5. 2JZ - GE:
REMOVE RELEASE CYLINDER WITH 3 BOLTS
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
Q01126
DISASSEMBLY
1. PULL OUT PUSH ROD WITH BOOT
2. REMOVE PISTON WITH SPRING
Using compressed air, remove the piston and spring from the
cylinder.
Q04338
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER
Z07291
COMPONENTS
See page CL-22
Plate Washer
Wave Washer
Flywheel
Snap Ring
Assembly
Plate Washer
Clutch Thrust Cone Spring
Clutch Release Hub
Snap Ring
x9
Pin
Wave
Washer
19 (195, 14)
Release Fork Support
Pilot Bearing
Release Fork Support Spring
REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE
(See page MT-2)
HINT:
Do not drain the transmission oil.
2. REMOVE RELEASE FORK ASSEMBLY
(a) Remove the release fork assembly from the left side of
clutch housing service hole.
Q04195
Q04196
Q04197
Q04198
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
Q04200
Q04201
Q04202
Q04204
Q04206
Q04207
SST
Q04208
Q04206
Q04203
Q04223
Q04327
INSTALLATION
1. INSTALL CLUTCH DISC AND COVER ON FLYWHEEL
Front (a) Insert SST in the clutch disc, then set them and the cover
SST
in position.
SST 09301-001 10
Z13786
Q04219
Q04403
Q04325
Q04218
Q04213
Q04222
Q04215
Q04216
Q04195
Pedal
Height
Q04185
Q00617
COMPONENTS
Filler Cap
Float
Pin Clip
Reservoir Tank Snap Ring
12 (125, 9)
REMOVAL
1. DRAIN OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE UNION
Using SST, disconnect the union nut.
SST 09023-00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. REMOVE CLIP AND PIN
4. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-
SST Q04188
TER CYLINDER
Torque: 12 N·m (125 kgf·cm, 9 ft·lbf)
DISASSEMBLY
1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the reservoir tank and grommet.
Q04189
Q04190
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH NEW SNAP
RING
Z08053
Protrusion
1.5 - 3.5 mm
(0.059 - 0.138 in.)
Q04313
TROUBLESHOOTING
MT06M-02
COMPONENTS
REMOVAL
1. REMOVE UPPER CONSOLE PANEL, SHIFT LEVER
BOOT RETAINER AND SHIFT AND SELECT LEVER
BOOTS NO.1 AND NO.2
(a) Remove the shift lever knob.
(b) Using a screwdriver, pry out the upper console panel.
(c) Remove the 4 bolts and boot retainer.
(d) Remove the shift and select lever boots No.1 and No.2.
Q04417
Q06365
R06858
Q06366
Matchmarks
Q04136
Q04137
Q04341
OIL SEAL
MT06Q-01
COMPONENTS
Adjusting Washer
Lock Nut
120 (1,220, 88)
Companion Flange
Oil Seal
Transmission
10 (100, 7)
26 (260, 19)
Release Fork Support
REPLACEMENT
1. REPLACE TRANSMISSION REAR OIL SEAL
(a) Remove the propeller shaft.
(See page PR-2 )
(b) Using a screwdriver, remove the lock plate.
Q04145
(c) Using SST to hold the flange, remove the lock nut.
SST 09330-00021
SST (d) Remove the 2 adjusting washers.
Q04146
Q04147
Q04148
Q04149
(k) Using SST to hold the flange, temporary install and torque
the lock nut.
SST
SST 09330-00021
Torque: 190 N·m (1,940 kgf·cm, 140 ft·lbf)
Q04150
(q) Using SST to hold the flange, reinstall and torque the lock
nut.
SST SST 09330-00021
Torque: 120 N·m (1,220 kgf·cm, 88 ft·lbf)
Q04150
Q04451
Q04152
Q04153
TROUBLESHOOTING
PR02H-01
INSTALLATION
1. 2JZ-GE:
INSTALL PROPELLER SHAFT
(a) Apply grease to the flexible coupling centering bushings.
Grease:
Molybdenum disulfide lithium base, NLGI No.2.
R06873
R07250
2. 2JZ-GTE:
INSTALL PROPELLER SHAFT
(a) Apply grease to the flexible coupling centering bushings.
Grease:
Molybdenum disulfide lithium base, NLGI No.1 or
No.2.
(b) Align the matchmarks on the flanges and connect the
flanges with the 4 nuts and washers.
R06873 (c) Torque the 4 nuts.
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
(d) Insert the propeller shaft from the vehicle’s rear and con-
nect the transmission and differential.
NOTICE:
Support the center support bearing by hand so that the
transmission and intermediate shaft, and propeller shaft
and differential, remain in a straight line.
(e) Temporarily install the 2 center support bearing set bolts
with the adjusting washers.
HINT:
Use the adjusting washers which were removed.
(f) Align the matchmarks and install the propeller shaft on
the differential with the 3 bolts, washers and nuts.
NOTICE:
Bolts should be inserted from the propeller shaft side.
Torque: 79 N·m (805 kgf·cm, 58 ft·lbf)
Z10404
ADJUSTMENT
NOTICE:
When doing operations which involve the removal and
installation of the propeller shaft, always check the joint.
Make adjustments if necessary.
R06878
R06879
R06880
(b) Using the SST, measure the installation angle of the dif-
ferential.
HINT:
Measure the installation angle by placing the SST in the posi-
tion, as shown in the illustration.
SST
R01139
>
No.2 Joint No.3 Joint +:
>
A - B = -1°09’ ± 36’ B - C = 44’ ± 36’
A B
No.2 Joint No.3 Joint
C
2JZ-GTE A - B = -1°09’ ± 36’ B - C = 44’ ± 36’
A
B
C
F01960
Example
-16’ -1’
Measurements (Installation angle):
Intermediate shaft: 1°50’
Propeller shaft: 2°14’
Differential: 2°15’
Joint angle:
No.2: 1°50’ - 2°14’ = -24’
No.3: 2°14’ - 2°15’ = -1’
R07370
Adjustment:
Center support bearing
Standard parts: 4 mm - 2 mm = 2 mm
Use adjusting washers which are 2 mm (0.079 in.)
thicker.
Differential
Use adjusting shims which are 1.6 mm (0.063 in.)
thicker.
R07371
HINT:
Maintain the same thickness for the adjusting washers
and adjusting shims on both the left and right sides.
If a washer and shim of the exact thickness are not avail-
able, use the parts which are the nearest in thickness.
NOTICE:
Check the joint angle once again after making the adjust-
ment.
2JZ-GE 2JZ-GTE Differential Adjusting Shim
Adjusting Washer
ADJUSTMENT CHART
No.2 Joint Angle
No.3 Joint Angle
Differential
Mount Upper
Stopper or
Adjusting Shim
R07372
COMPONENTS
2JZ-GE
74 (750, 54)
Washer Plate
Washer
Dust Deflector
REMOVAL
1. REMOVE OXYGEN SENSOR
(a) Remove the 2 bolts.
(b) Remove the oxygen sensor and heat insulator.
2. REMOVE EXHAUST PIPE (See page EM-94)
3. REMOVE HEAT INSULATOR
Remove the 4 nuts and heat insulator.
4. NORMAL ROOF:
REMOVE CENTER FLOOR CROSSMEMBER BRACE
Remove the 4 bolts and crossmember brace.
5. SPORT ROOF:
REMOVE CENTER FLOOR CROSSMEMBER BRACE
Remove the 6 bolts and crossmember brace.
6. 2JZ-GE:
REMOVE PROPELLER SHAFT
(a) Remove the 2 center support bearing set bolts and ad-
justing washers.
HINT:
Production vehicles are not equipped with adjusting washers.
NOTICE:
When removing the set bolts, support the center support
R06868 bearing by hand so that the transmission and intermediate
shaft, and propeller shaft and differential, remain in a
straight line.
R07621
(f) M/T:
Install SST in the transmission to prevent oil leakage.
SST 09325-20010
(g) A/T:
Install SST in the transmission to prevent oil leakage.
SST 09325-40010
SST
R06872
7. 2JZ-GTE:
REMOVE PROPELLER SHAFT
(a) Using SST, loosen the adjusting nut until it can be turned
SST by hand.
SST 09922-10010
HINT:
Use 2 of the same type SST.
R06864
R06865
Matchmarks
R06869
(g) Remove the 2 center support bearing set bolts and ad-
justing washers.
HINT:
Some vehicles are not equipped with and adjusting washer.
NOTICE:
When removing the set bolts, support the center support
bearing by hand so that the transmission and intermediate
shaft, and propeller shaft and differential, remain in a
R06867 straight line.
(h) Remove the propeller shaft from the transmission.
(i) Push the rear propeller shaft straight forward to compress
the propeller shaft and pull out the propeller shaft from the
centering pin of the differential.
NOTICE:
Press the propeller shaft straight ahead to keep the trans-
mission and intermediate shaft aligned straight.
(j) Pull the propeller shaft out toward the vehicle’s rear.
NOTICE:
The intermediate shaft and propeller shaft should not be
separated.
INSPECTION
1. INSPECT CENTER SUPPORT BEARING
(a) Check if the bearing turns smoothly.
(b) Check for crack in or damage to the cushion.
If the center support bearing is damaged, worn or does not turn
smoothly, replace it.
PR0260
R07008
R06873
R01130
R01131
REPLACEMENT
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
the vise as this will cause deformation.
Matchmarks
1. 2JZ-GE:
REPLACE CENTER SUPPORT BEARING
(a) Separate the propeller shaft and intermediate shaft.
(1) Place matchmarks on the flanges.
(2) Remove the 4 bolts, washers and nuts.
(b) Remove the center support bearing from intermediate
shaft.
(1) Using a chisel and hammer, loosen the staked part
R06958 of the nut.
SST
R01128
R01129
(2) Place the flange on the shaft and align the match-
Matchmarks marks.
HINT:
If replacing either the center flange or intermediate shaft, reas-
semble them so that the front yoke of the intermediate shaft and
the rear yoke of the propeller shaft are facing in the same direc-
tion.
(3) Install the washer.
R01132
(4) Using SST to hold the flange, press the bearing into
position by tightening down a new nut.
SST 09330-00021
Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
(5) Loosen the nut.
(6) Torque the nut again.
SST Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(7) Using a punch and hammer, stake the shaft.
R01133
Q06357
PR0228
R07314
PR0229