Toyota Camry

 XV30 (2002–2006) Service Manual

Clutch
Clutch pedal sub-assy

1. INSPECT AND ADJUST CLUTCH PEDAL SUB−ASSY

1. Turn over the floor carpet.

2. Check that the pedal height is correct.

   Pedal height from asphalt sheet: 159.0 to 169.0 mm (6.260 − 6.654 in.)

3. Adjust the pedal height.

1. Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut.

Torque: 26 N·m (260 kgf·cm, 19 ft·lbf)

d. 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 to 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.)

e. Adjust the pedal free play and push rod play.

1. Remove the instrument panel sub−assy upper.

2. Remove the instrument panel insert sub−assy lower LH.

3. Disconnect the air duct.

4. Loosen the lock nut and turn the push rod until the free play and push rod play are correct.

5. Tighten the lock nut.

6.  After adjusting the pedal free play, check the pedal height.

7. Connect the air duct.

8. Install the instrument panel insert sub−assy lower LH.

9. Install the instrument panel sub−assy upper.

f. Check the clutch release point.

1. Pull the parking brake lever and install wheel stopper.

2. Start the engine and idle the engine.

3. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact.

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.

Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point)

If the distance is not as specified, perform the following operations.

• Check pedal height.

• Check push rod play and pedal free play.

• Bleed the clutch line.

• Check the clutch cover assy and disc assy.

Clutch system (From July, 2003)

Clutch release cylinder assy

Clutch accumulator assy

Clutch unit

Clutch start switch assy

Clutch pedal sub-assy

Clutch start switch assy

Clutch pedal sub-assy

Clutch master cylinder assy