boot TOYOTA CAMRY V20 1986 Service Information

ASSEMBLY OF CYLINDER
(See page BR±34)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
FOLLOWING PARTS:
(a) Main pin boot
(b) Sliding bushing and dust boots
(e) Piston, piston seal and cylinder boot
5. INSTALL SLIDING BUSHING AND DUST BOOTS
(a) Install the sliding bushing and dust boots into the
brake cylinder.
(b) Insure that the boots are secured firmly to the brake
cylinder groove. 3. INSTALL CYLINDER BOOT AND SET RING IN
CYLINDER
4. INSTALL MAIN PIN BOOT
Install the main pin boot in place. 2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
± BRAKE SYSTEMRear BrakeBR±40

REMOVAL OF MASTER CYLINDER
1. DRAW OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE TUBE
3. REMOVE INSTRUMENT LOWER FINISH PANEL
Remove the lower instrument lower finish panel and disconnect
the air duct from the instrument lower finish panel.
4. REMOVE CLEVIS PIN AND CLIP WITH SPRING
WASHER
Remove the clip and clevis pin with the spring washer.
5. REMOVE MOUNTING NUTS AND PULL OUT MASTER
CYLINDER
DISASSEMBLY OF MASTER CYLINDER
1. REMOVE RESERVOIR TANK
2. REMOVE PUSH ROD AND PISTON
(a) Pull back the boot and, using snap ring pliers, remove the snap
ring.
(b) Pull out the push rod.
CLUTCH MASTER CYLINDER
COMPONENTS
± CLUTCHClutch Master CylinderCL±5

REMOVAL OF RELEASE CYLINDER
1. DISCONNECT CLUTCH LINE TUBE
Using SST, disconnect the tube. Use a container to catch
the brake fluid.
SST 09751±36011
2. REMOVE TWO BOLTS AND PULL OUT RELEASE
CYLINDER
3. REMOVE PISTON WITH SPRING
(a) Remove the boot and push rod from the cylinder.
(b) Using compressed air, remove the piston with spring
from the cylinder.
CLUTCH RELEASE CYLINDER
COMPONENTS
± CLUTCHClutch Release CylinderCL±7

INSPECTION OF RELEASE CYLINDER
HINT: Clean the disassembled part with compressed air.
1. INSPECT RELEASE CYLINDER BORE FOR SCORING
OR CORROSION
If a problem is found, clean or replace the cylinder.
2. INSPECT PISTON AND CUPS FOR WEAR, SCORING.
CRACKS OR SWELLING
If either one requires replacement, use the parts from the
cylinder kit.
3. INSPECT PUSH ROD FOR WEAR OR DAMAGE
If necessary, replace the push rod.
INSTALLATION OF RELEASE CYLINDER
(see page CL±7)
1. INSTALL RELEASE CYLINDER WITH TWO BOLTS
2. CONNECT CLUTCH LINE TUBE
Using SST, connect the tube.
SST. 09751±36011
Torque: 155 kg±cm (11 ft±Ib, 15 N±m)
3. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND
BLEED CLUTCH SYSTEM
(See page CL±4)
4. CHECK FOR LEAKS
ASSEMBLY OF RELEASE CYLINDER
(see page CL±7)
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON WITH SPRING
3. INSTALL BOOT AND INSERT PUSH ROD
± CLUTCHClutch Release CylinderCL±8

4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth
and width of wear.
Maximum: Depth 0.6 mm (0.024 in.)
Width 5.0 mm (0.197 in.)
If necessary, replace the clutch cover. 3. REMOVE RELEASE BEARING, FORK AND BOOT
FROM TRANSAXLE
(a) Remove the bearing assembly together with the fork,
and then separate them.
(b) Remove the boot.
INSPECTION AND REPAIR OF CLUTCH
PARTS
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 a problem is found, 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 is excessive, replace the flywheel. 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.
± CLUTCHClutch UnitCL±10

4. INSTALL RELEASE BEARING, FORK AND BOOT
FROM TRANSAXLE
(a) Install the bearing assembly to the fork, and then install
them to the transaxle.
(b) Install the boot.(d) Clutch disc spline.
(e) (S51 Transaxle)
Release bearing hub inside groove.
5. INSTALL TRANSAXLE TO ENGINE
E56F5 Transaxle (SV series/4WD) S51 Transaxle (SV series/2WD)
E52 Transaxle (M series)Transaxle
See page
MT± 116 MT±45
MT±38
± CLUTCHClutch UnitCL±12

17. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEY
HINT (Re±using timing belt): If the installation marks have
disappeared, before removing the timing belt, place new
instillation marks on the timing belt to match the timing marks
of the camshaft timing pulleys.
(a) Using SST, loosen± the tension between the LH and
RH camshaft timing pulleys by slightly turning the RH
camshaft timing pulley clockwise.
SST 09278±54012 15. SET NO.1 CYLINDER TO TDCI COMPRESSION
(a) Turn the crankshaft pulley and align its groove with the timing
mark º0º of the No.1 timing belt cover.
(b) Check that timing marks of the camshaft timing
pulleys and No±3 timing belt cover are aligned.
If not, turn the crankshaft one revolution (360
°).
16. REMOVE TIMING BELT TENSIONER
Remove the two bolts, tensioner and dust boot.
± ENGINE MECHANICALTiming Belt (2VZ±FE)EM±36

12. SET TIMING BELT TENSIONER
(a) Place a plate washer between the tensioner and a block.
(b) Using a press, slowly press in the push rod using 100
± 1,000 kg (220 ± 2,205 ib, 981 ± 9,807 N) of pressure.
(c) Align the holes of the push rod and housing, pass a
1.27 mm hexagon wrench (sized 1.27 mm) through the
holes to keep the setting position of the push rod.
(d) Release the press.
(e) Install the dust boot to the tensioner. (g) Using SST, install and torque the bolt.
SST09249±63010 and 09278±54012
Torque: 760 kg±cm (55 ft±lb, 75 N±m)
HINT: Use a torque wrench with a fulcrum length of 340
mm (13.39 in.). (f) Using SST, align the knock pin hole of the camshaft with
the knock pin groove of the pulley and install the
knock pin.
SST 09278±54012
13. INSTALL TIMING BELT TENSIONER
(a) Install the tensioner with the two bolts.
Torque: 270 kg±cm (20 ft±lb, 26 N±m)
± ENGINE MECHANICALTiming Belt (2VZ±FE)EM±45

HINT:
wCaster changes 30' with each spacer.
wDo not install more than two spacers.
8. INSPECT TOE±IN
Measure toe±in with a toe±in gauge in the following
procedure.
(a) Bounce the vehicle up and down to stabilize the sus-
pension.
(b) Move the vehicle forward about 5 m (16.4 ft ) with the
front wheel in the straight±ahead position on a level
place.
(c) Mark the center of each rear tread and measure the
distance between the marks of the right and left tires.
(e) Measure the distance between the marks on the
front of the tires.
Inspection standard: 1
+ 2 mm (0.04 + 0.08 in.)
If necessary, adjust the toe±in.(d) Advance the vehicle until the marks on the rear
sides of the tires come to the measuring heights
of the gauge on the front side.
HINT: If the tire rolls too far, repeat from step (b).
9. ADJUST TOE±!N
(a) Remove the boot clips.
(b) Loosen the tie rod end lock nut.
± FRONT AXLE AND SUSPENSIONFront Wheel AlignmentFA ± 5

HINT: Insure that the lengths of the left and right
tie rod ends length are the same.
Tie rod end length left±right error:
Less than 1.5 mm (0.059 in.)
(d) Torque the tie rod end lock nuts.
Torque: 570 kg±cm (41 ft±lb , 56 N±M)
(e) Place the boot on the seat and clamp it.
HINT: Insure that the boots are not twisted.(e) Turn the left and right tie rod ends an equal amount to
adjust the toe±in.
Adjustment standard: 1 + 1 mm (0.04 + 0.04 in.)
10. INSPECT SIDE SLIP (REFERENCE ONLY)
Side slip: Less than 3.0 mm/m (0.118 in./3.3 ft)
± FRONT AXLE AND SUSPENSIONFront Wheel AlignmentFA ± 6