Page 1057 of 2543

SERVICE SPECIFICATIONS
SERVICE DATA
Battery
Voltage (Maintenance±free battery) at 205C (685F)
Specific gravity (Except maintenance±free battery)
at 205C(685F)
12.7±12.9 V
1.27±1.29
Generator
Rated output 2JZ±GE
2JZ±GTE
Rotor coil resistance at 205C (685C)
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum
12 V 90 A
12 V 100 A
2.8±3.0
14.2±14.4 mm (0.559±0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
Voltage
regulator
Regulating voltage at 255C (775F)
at 1155C (2395F)
13.6±14.8 V
13.2±14.0 V
TORQUE SPECIFICATIONS
Part tightened NVm kgfVcm ftVlbf Rectifier end frame X Drive end frame 4.5 46 40 in.Vlbf
Generator pulley X Rotor
11 0
1,125
81
Rectifier holder X Coil lead on rectifier end frame 2.0 20 17 in.Vlbf
Rear end cover X Rectifier holder 4.5 46 40 in.Vlbf
Plate terminal X Rectifier holder 3.9 40 35 in.Vlbf
Terminal insulator X Rectifier holder 6.5 66 58 in.Vlbf
Generator X Water pump 37 380 27
Generator X Cylinder block 37 380 27
± CHARGING SYSTEMSERVICE SPECIFICATIONSCH±20
Page 1058 of 2543
Page 1059 of 2543
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09023±00100 Union Nut Wrench 10 mm
09301±00110 Clutch Guide Tool
Clutch line
09303±35011 Input Shaft Front Bearing Puller
09304±30012 Input Shaft Front Bearing
Replacer
09333±00013 Clutch Diaphragm Spring Aligner
2JZ±GE Only
RECOMMENDED TOOLS
09082±00050 TOYOTA Electrical Tester Set
09905±00012Snap Ring No. 1 Expander
EQUIPMENT
Calipers
Dial indicator Dial indicator
To rque wrench Torque wrench
CL±2± CLUTCHPREPARATION
Page 1060 of 2543

TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
CL±4CL±6CL±11See page
Parts Name
Trouble
Clutch grabs/chatters
Clutch noisy
Clutch slips
Clutch pedal spongy
Clutch does not disengage
Clutch pedal (freeplay out of adjustment)Pilot bearing (Worn or damaged)Release bearing (Worn, dirty or damaged)Engine mounting (loosen)Release cylinder cup (Damaged)master cylinder cup (Damaged)Clutch line (Air in line)Clutch disc (Dirty or burred)Clutch disc (Oily)Clutch disc (Worn out)Clutch disc torsion rubber (Damaged)Clutch disc (Out of true)Input shaft bearing (Worn or damaged)Clutch disc (Lining broken)Clutch disc (Runout is excessive)Clutch disc (Lack of spline grease)Diaphragm spring (Damaged)Clutch disc (Glazed)Diaphragm spring (Out of tip alignment)Pressure plate (Distortion)Flywheel (Distortion)
CL±17CL±8CL±9CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±15CL±21CL±11CL±17CL±15CL±20CL±11CL±17
± CLUTCHTROUBLESHOOTINGCL±3
Page 1061 of 2543

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
Page 1062 of 2543
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
Page 1063 of 2543
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
Page 1064 of 2543
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