TOYOTA TERCEL 1996 Service Repair Manual

CL05R-01
Q06660
SST
- CLUTCHCLUTCH MASTER CYLINDER
CL-5
1996 TERCEL (RM440U)
REMOVAL
1. DRAW OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
3. REMOVE CLIP AND CLEVIS PIN
4. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-
TER CYLINDER
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

CL05S-01
CL0659
CL0660
CL-6
- CLUTCHCLUTCH MASTER CYLINDER
1996 TERCEL (RM440U)
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
Pull off the boot, and using snap ring pliers, remove the snap
ring.
3. REMOVE PISTON

CL05T-01
CL0528
CL0652
Protrusion
1.5 - 3.5 mm
(0.059 - 0.138 in.)
- CLUTCHCLUTCH MASTER CYLINDER
CL-7
1996 TERCEL (RM440U)
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH 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.

CL05U-03
CL-8
- CLUTCHCLUTCH MASTER CYLINDER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CL-5).
HINT:
After installation, bleed system and adjust clutch pedal.

CL05V-03
Z14165
Release Cylinder
Spring
Piston
Push Rod
Boot Clutch Line
- CLUTCHCLUTCH RELEASE CYLINDER
CL-9
704 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH RELEASE CYLINDER
COMPONENTS

CL05W-01
Q06706SST CL-10
- CLUTCHCLUTCH RELEASE CYLINDER
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

CL05X-01
Q06678
- CLUTCHCLUTCH RELEASE CYLINDER
CL-1 1
1996 TERCEL (RM440U)
DISASSEMBLY
1. PULL OUT BOOT WITH PUSH ROD
2. REMOVE PISTON
Using compressed air, remove the piston with the spring from
the cylinder.

CL05Y-01
CL0672
CL-12
- CLUTCHCLUTCH RELEASE CYLINDER
1996 TERCEL (RM440U)
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

CL05Z-03
- CLUTCHCLUTCH RELEASE CYLINDER
CL-13
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CL-10).
HINT:
After installation, bleed clutch system.

CL060-03
Z14164
Flywheel
Clutch Disc
Clutch Cover
Boot Release Fork Release Bearing with Hub X6 CL-14
- CLUTCHCLUTCH UNIT
709 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH UNIT
COMPONENTS