TOYOTA SUPRA 1995 Service Repair Manual

CLUTCH PEDAL
CLUTCH PEDAL CHECK AND ADJUSTMENT
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
146.2±156.2 mm (5.76±6.15 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and clutch switch until the height is cor-
rect. Tighten the lock nut.
HINT: Before rotating the clutch switch for pedal height ad-
justment, disconnect the clutch switch connector.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance
is felt.
Pedal freeplay: 5.0±15.0 mm (0.197±0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0±5.0 mm (0.039±0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH
ROD PLAY
(a) Loosen the lock nut and turn the push rod until the freeplay
and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
5. INSPECT FULL PEDAL STROKE
Full pedal stroke: 132.0±138.0 mm (5.20±5.43 in.)
6. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into position until the gears contact.
(d) Gradually depress the clutch pedal and measure the stroke
distance from the point 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, do the following operation.
wInspect pedal height.
wInspect push rod play and pedal freeplay.
wBleed the clutch line.
wInspect the clutch cover and disc. CL±4
± CLUTCHCLUTCH PEDAL

7. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch pedal
is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, adjust or replace the clutch start switch.
8. INSPECT CONTINUITY OF CLUTCH START SWITCH
(a) Check that there is continuity between terminals when the
switch is ON (pushed).
(b) Check that there is no continuity between terminals when the
switch is OFF (free).
If continuity is not as specified, replace the switch.
± CLUTCHCLUTCH PEDALCL±5

CLUTCH MASTER CYLINDER
COMPONENTS
MASTER CYLINDER REMOVAL
Installation is in the reverse order of removal.
1. DRAIN OUT FLUID WITH SYRINGE
INSTALLATION HINT: After installation, adjust the clutch
pedal and bleed the clutch system.
2. DISCONNECT CLUTCH LINE UNION
Using SST, disconnect the union nut.
SST 09023±00100
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
3. REMOVE CLIP AND PIN
4. REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER
CYLINDER
Torque: 12 NVm (125 kgfVcm, 9 ftVlbf)
CL±6± CLUTCHCLUTCH MASTER CYLINDER

MASTER CYLINDER 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.
2. REMOVE PUSH ROD
(a) Pull back the boot, and using snap ring pliers, remove the
snap ring.
(b) Pull out the push rod.
3. REMOVE PISTON
MASTER CYLINDER ASSEMBLY
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
4. INSTALL RESERVOIR TANK
(a) Install the reservoir tank and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring pin.
± CLUTCHCLUTCH MASTER CYLINDERCL±7

CLUTCH RELEASE CYLINDER
(2JZ±GTE)
COMPONENTS
RELEASE CYLINDER REMOVAL
Installation is in the reverse order of removal.
INSTALLATION HINT: After installation, adjust the clutch
pedal and bleed the clutch system.
1. REMOVE CLUTCH HOUSING COVER LH
Remove the 2 bolts.
Torque: 12 NVm (120 kgfVcm, 9 ftVlbf)
2. DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container
to catch the fluid.
SST 09023±00100
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
3. REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER
Torque: 12 NVm (120 kgfVcm, 9 ftVlbf)
CL±8± CLUTCHCLUTCH RELEASE CYLINDER (2JZ±GTE)

RELEASE CYLINDER DISASSEMBLY
1. PULL OUT PUSH ROD WITH BOOT
2. REMOVE PISTON WITH SPRING
Using compressed air, remove the piston and spring from the
cylinder.
RELEASE CYLINDER ASSEMBLY
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
CLUTCH RELEASE CYLINDER
(2JZ±GE)
COMPONENTS
± CLUTCHCLUTCH RELEASE CYLINDER (2JZ±GTE, 2JZ±GE)CL±9

RELEASE CYLINDER REMOVAL
Installation is in the reverse order of removal.
INSTALLATION HINT: After installation, adjust the clutch
pedal and bleed the clutch system.
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line union. Use a container
to catch the fluid.
SST 09023±00100
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
2. REMOVE RELEASE CYLINDER WITH 3 BOLTS
Torque:
A: 12 NVm (120 kgfVcm, 9 ftVlbf)
B: 4.9 NVm (50 kgfVcm, 43 in.Vlbf)
RELEASE CYLINDER DISASSEMBLY
1. PULL OUT PUSH ROD WITH BOOT
2. REMOVE PISTON WITH SPRING
Using compressed air, remove the piston and spring from the
cylinder.
RELEASE CYLINDER ASSEMBLY
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 CL±10
± CLUTCHCLUTCH RELEASE CYLINDER (2JZ±GE)

CLUTCH UNIT (2JZ±GTE)
COMPONENTS
CLUTCH UNIT REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE
(See page MT2±5)
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.
(b) Remove the E±ring from the release fork.
(c) Remove the pin and wave washer from the release fork.
± CLUTCHCLUTCH RELEASE CYLINDER(2JZ±GTE)CL±11

3. REMOVE CLUTCH DISC
4. REMOVE CLUTCH COVER ASSEMBLY
5. REMOVE CLUTCH RELEASE BEARING HUB
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the release bearing hub, thrust cone spring and
plate washer.
6. REMOVE CLUTCH RELEASE BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the release bearing, wave washer and plate washer.
CLUTCH PARTS INSPECTION AND
REPAIR
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth:
0.3 mm (0.012 in.)
If a problem is found, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout:
0.8 mm (0.031 in.)
If runout is excessive, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout:
0.1 mm (0.004 in.)
If runout excessive, replace the flywheel. CL±12
± CLUTCHCLUTCH UNIT (2JZ±GTE)

4. INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the axial
direction.
If the bearing sticks or has much resistance, replace the pilot
bearing.
5. IF NECESSARY, REPLACE PILOT BEARING
(a) Remove the 2 bolts at diametrically opposite points.
(b) Using SST, remove the pilot bearing.
SST 09303±35011
(c) Using SST and a hammer, drive in a new pilot bearing.
SST 09301±00110
(d) Install 2 new bolts.
(e) First, torque the 2 bolts uniformly a little at a time.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
(f) Then tighten the 2 bolts an additional 80±100°.
± CLUTCHCLUTCH UNIT (2JZ±GTE)CL±13