Hilux 2015 2018 manual clutch he thong ly hop

Tài liệu hướng dẫn sửa chữa Hệ thống ly hợp trên xe Hilux 2015 2018 manual clutch he thong ly hop . Cung cấp các thông tin cần thiết cho Kỹ thuật viên các thông tin cần thiết để tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác, hợp lý

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Page 1 of 2 https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MJUK.html?PUB_TYPE=RM&MODE=1

CLUTCH CLUTCH ACCUMULATOR COMPONENTS

ILLUSTRATION

*1 CLUTCH ACCUMULATOR ASSEMBLY *2 MASTER CYLINDER TO FLEXIBLE HOSE TUBE

*3 ACCUMULATOR TO FLEXIBLE HOSE TUBE -

-Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping" : N*m (kgf*cm,ft.*lbf)

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

* For use with union nut wrench -

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Check for leaks in the clutch system

Install the clutch accumulator assembly with the 2 nuts

*a Torque Wrench Fulcrum Length

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 (fulcrumlength of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

·

2.BLEED AIR FROM CLUTCH PIPE LINE

3.CHECK FOR CLUTCH FLUID LEAKAGE

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Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING

4.CHECK FLUID LEVEL IN RESERVOIR

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CLUTCH CLUTCH ACCUMULATOR REMOVAL

PROCEDURE

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

a.

Remove the 2 nuts and clutch accumulator assembly

b.

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Page 1 of 2 https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MJU8.html?PUB_TYPE=RM&MODE=1

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 FLEXIBLEHOSE TUBE

*3 CLUTCH RESERVOIR TUBE *4 MASTER CYLINDER BRACKET

-Tightening torque for "Major areas involvingbasic vehicle performance such as

● Non-reusable part * For use with union nut wrench

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*A w/ Intelligent Manual Transmission *B w/ Master Cylinder Bracket

*1 CLUTCH MASTER CYLINDER ASSEMBLY *2 CLUTCH MASTER CYLINDER TO FLEXIBLEHOSE TUBE

*3 CLUTCH RESERVOIR TUBE *4 INTELLIGENT MANUAL TRANSMISSIONCONNECTOR

*5 MASTER CYLINDER BRACKET *6 CLEVIS PIN

Tightening torque for "Major areas involvingbasic vehicle performance such as

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CLUTCH CLUTCH MASTER CYLINDER(w/ Turn Over) INSTALLATION

CAUTION / NOTICE / HINT

HINT:

PROCEDURE

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>INSTALLATION

Use the same procedure for RHD and LHD vehicles

·

The procedure listed below is for LHD vehicles

·

w/o Master Cylinder Bracket:

2.CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

3.CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE 31481

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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:

a.

*A w/o Intelligent Manual Transmission

*B w/ Intelligent Manual Transmission

·

Connect the clutch reservoir tube to the clutch master cylinder assembly, and slide the clip to secure it

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HINT:

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>ADJUSTMENT

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*a Dry Cell Battery

*b Clutch Pedal Condition

Connection

Condition (Clutch Pedal) Standard

2(CLS)

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

2(CLS) 1(ECLS) Depressed 3.828 to 4.452V

-Standard Voltage (When 5 V Applied) Tester

Connection

Condition (Clutch Pedal) Standard

2(CLS)

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CLUTCH CLUTCH MASTER CYLINDER(w/ Turn Over) REMOVAL

HINT:

PROCEDURE

NOTICE:

Wash off clutch fluid immediately if it comes into contact with a painted surface

·

1.DRAIN CLUTCH FLUID

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

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Slide the clip and disconnect the clutch reservoir tube from the clutch master cylinder assembly

HINT:

Use a container to collect the fluid

a.

4.DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE 31481

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Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>REMOVAL

Using a union nut wrench, disconnect the clutch master cylinder to flexible hose tube from the clutch

master cylinder assembly

HINT:

a.

5.DISCONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

a.

Remove the 2 nuts, clutch master cylinder assembly and gasket

i.

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w/ Master Cylinder Bracket:

b.

Remove the 2 nuts, clutch master cylinder assembly, master cylinder bracket and 2 gaskets

i.

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

ILLUSTRATION

-*1 CLUTCH MASTER CYLINDER ASSEMBLY *2 CLUTCH MASTER CYLINDER PUSH RODCLEVIS

*3 CLUTCH MASTER CYLINDER TO FLEXIBLEHOSE TUBE *4 CLUTCH RESERVOIR TUBE

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

ILLUSTRATION

-*1 CLUTCH MASTER CYLINDER ASSEMBLY *2 CLUTCH MASTER CYLINDER PUSH RODCLEVIS

*3 CLUTCH MASTER CYLINDER TO FLEXIBLEHOSE TUBE *4 CLUTCH RESERVOIR TUBE

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

HINT:

PROCEDURE

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>INSTALLATION

·

1.INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

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

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)

a.

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)

b.

3.CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

4.CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE 31481

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HINT:

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:

a.

·

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

a.

6.BLEED AIR FROM CLUTCH PIPE LINE

8.INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY 31301

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

HINT:

PROCEDURE

NOTICE:

Wash off clutch fluid immediately if it comes into contact with a painted surface

·

1.DRAIN CLUTCH FLUID

Slide the clip and disconnect the clutch reservoir tube from the clutch master cylinder assembly

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Click hereDrivetrain>CLUTCH>CLUTCH PEDAL>REMOVAL

Using a union nut wrench, disconnect the clutch master cylinder to flexible hose tube

HINT:

a.

Remove the 2 nuts, clutch master cylinder assembly and gasket

a.

w/ Master Cylinder Bracket:

Remove the 2 nuts, clutch master cylinder assembly, master cylinder bracket and 2 gaskets

b.

6.REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS

Loosen the lock nut, and then remove the master cylinder push rod clevis and lock nut from the push rod

NOTICE:

When loosening the lock nut, be sure to hold the clevis in place by its square portion

a.

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CLUTCH CLUTCH PEDAL ADJUSTMENT

PROCEDURE

1.INSPECT AND ADJUST CLUTCH PEDAL ASSEMBLY

Fold back the floor carpet to expose the asphalt sheet under the pedal

a.

Check that the pedal height is correct

Pedal height from floor panel:

176.3 to 186.3 mm (6.95 to 7.33 in.)

b.

*a Pedal Height

*b Pedal Height Adjustment Point

*c Push Rod Play

*d Push Rod Play Adjustment Point

Adjust the pedal height

Adjust the clutch switch assembly

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL SWITCH>INSTALLATION

iv.

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Check the pedal free play and push rod play

HINT:

Pay close attention to the change in resistance to distinguish between pedal free play and push rod play

while performing the inspection

d.

*a Push Rod Play

*b Pedal Free Play

Depress the clutch pedal until resistance is felt

The push rod play can be adjusted by changing the length of the push rod Pedal free play changes

together with push rod play

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Check the clutch release point

f.

*a 25 mm or more

*b Release Point

*c Pedal Stroke

*d Full Stroke End Position

Pull the parking brake lever and use wheel chocks to stabilize the vehicle

·Bleed air from clutch line

·Check clutch cover and disc

·

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CLUTCH CLUTCH PEDAL COMPONENTS

ILLUSTRATION

-*1 CLUTCH MASTER CYLINDER PUSH RODCLEVIS *2 CLUTCH MASTER CYLINDER PUSH RODCLEVIS BUSH

*5 CLUTCH PEDAL SUB-ASSEMBLY *6 CLUTCH SWITCH ASSEMBLY

*7 NO 1 CLUTCH PEDAL CUSHION *8 NO 2 CLUTCH PEDAL CUSHION

*11 CLUTCH PEDAL SUPPORT SUB-ASSEMBLY *12 CLUTCH PEDAL BUSH

*15 CLUTCH START SWITCH *16 CLUTCH SWITCH CONNECTOR

*17 CLUTCH START SWITCH CONNECTOR -

-N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

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ILLUSTRATION

*1 CLUTCH MASTER CYLINDER PUSH RODCLEVIS *2 CLUTCH MASTER CYLINDER PUSH RODCLEVIS BUSH

*5 CLUTCH PEDAL SPRING *6 CLUTCH PEDAL SPRING HOLDER

*7 CLUTCH PEDAL SUB-ASSEMBLY *8 CLUTCH PEDAL TURNOVER BUSH

*9 CLUTCH SWITCH ASSEMBLY *10 NO 1 CLUTCH PEDAL CUSHION

*11 NO 2 CLUTCH PEDAL CUSHION *12 PEDAL SPRING HOOK

*17 PEDAL SPRING WITH HOOK *18 CLUTCH START SWITCH ASSEMBLYCONNECTOR

*21 CLUTCH SWITCH ASSEMBLY CONNECTOR -

-N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

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CLUTCH CLUTCH PEDAL INSTALLATION

PROCEDURE

Install the No 2 clutch pedal cushion to the clutch pedal sub-assembly

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Apply MP grease to the contact surface of the pedal spring hook and install the pedal spring hook to the

clutch pedal support sub-assembly

3.INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH 31453B

Apply MP grease to the inside of a new clutch master cylinder push rod clevis bush

Install the No 1 clutch pedal cushion to the clutch pedal sub-assembly

a.

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Apply MP grease to the collar and the inside and outside of 2 new clutch pedal bushes

a.

MP grease

Install the 2 clutch pedal bushes and collar to the clutch pedal sub-assembly

b.

6.INSTALL CLUTCH PEDAL TURNOVER BUSH (w/ Turn Over) 31301P

Apply MP grease to the inside of the clutch pedal turnover bush and install the bush to the clutch pedal

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Apply MP grease to the contact surface of the clutch pedal spring holder and install the clutch pedal springholder to the clutch pedal support sub-assembly

a.

MP grease

Install the clutch pedal sub-assembly to the clutch pedal support sub-assembly with the bolt and nut

9.INSTALL CLUTCH PEDAL SPRING (w/ Turn Over)

Move the pedal to the full stroke position

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Click hereDrivetrain>CLUTCH>CLUTCH PEDAL SWITCH>INSTALLATION

Install the pedal spring with hook

d.

Install in this Direction

11.INSTALL CLUTCH SWITCH ASSEMBLY (w/ Clutch Switch Assembly) 88280A

13.INSTALL CLUTCH PEDAL SUPPORT ASSEMBLY

Install the clutch pedal support assembly with the bolt and 2 nuts

Torque:

for nut A : 18.4 N*m (188 kgf*cm, 14 ft.*lbf) for bolt B : 18 N*m (184 kgf*cm, 13 ft.*lbf)

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Click hereVehicle Interior>INTERIOR PANELS / TRIM>UPPER INSTRUMENT PANEL>INSTALLATION

Apply MP grease to the contact surface of the clevis pin

15.INSPECT AND ADJUST CLUTCH PEDAL ASSEMBLY

16.INSTALL INSTRUMENT UPPER PANEL SUB-ASSEMBLY 55302A

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CLUTCH CLUTCH PEDAL REMOVAL

PROCEDURE

Click hereVehicle Interior>INTERIOR PANELS / TRIM>UPPER INSTRUMENT PANEL>REMOVAL

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL SWITCH>REMOVAL

1.REMOVE INSTRUMENT UPPER PANEL SUB-ASSEMBLY 55302A

3.REMOVE CLUTCH PEDAL SUPPORT ASSEMBLY

Disconnect the clutch switch connector

a.

Remove the bolt, 2 nuts and clutch pedal support assembly

b.

5.REMOVE CLUTCH SWITCH ASSEMBLY (w/ Clutch Switch Assembly) 88280A

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Click hereDrivetrain>CLUTCH>CLUTCH PEDAL SWITCH>REMOVAL

7.REMOVE CLUTCH PEDAL SPRING (w/ Turn Over)

Move the pedal to the full stroke position and remove the clutch pedal spring

a.

Remove the pedal spring with hook

b.

Remove in this Direction

a.

Tiêu đề	Hilux 2015 2018 Manual Clutch He Thong Ly Hop
Trường học	Toyota Motor Corporation
Chuyên ngành	Automotive Engineering
Thể loại	Service Manual
Năm xuất bản	2017
Thành phố	Not Specified

Định dạng
Số trang	76
Dung lượng	2,57 MB
File đính kèm	Hilux 2015-2018 Manual_Clutch_He thong ly hop.zip (2 MB)