Page 1065 of 2543
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)
Page 1066 of 2543
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
Page 1067 of 2543
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)
Page 1068 of 2543
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
Page 1069 of 2543
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)
Page 1070 of 2543
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
Page 1071 of 2543

6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum:
A: Depth 0.6 mm (0.024 in.)
B: Width 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial
direction.
HINT: The bearing is permanently lubricated and requires no
cleaning or lubrication.
If a problem is found, replace the bearing together with the
hub.
8. INSPECT FLYWHEEL DAMPER FOR GREASE LEAKAGE
If grease has sprayed onto the clutch housing, replace the fly-
wheel assembly.
9. INSPECT FLYWHEEL DAMPER ROTATIONAL
FREEPLAY
(a) Install the 2 bolts to the secondary flywheel at diametrically
opposite positions.
(b) Holding both the bolts, turn the secondary flywheel clockwise
until it stops.
(c) Put matchmarks on the primary and secondary fly±wheels at
this position.
(d) Then rotate the primary flywheel counterclockwise by hand
until it stops.
(e) Put matchmarks on the primary flywheel at this position.
(f) M e a s u r e t h e c i r c u m f e r e n t i a l length between the 2
matchmarks on the secondary flywheel.
Standard:
105 mm (4.134 in.)
(g) Repeat the preceding steps (d) to (f) 4 times and if the
measurement is greater than the maximum length replace
the flywheel assembly.
(See page EG±122) CL±14
± CLUTCHCLUTCH UNIT (2JZ±GTE)
Page 1072 of 2543

CLUTCH UNIT INSTALLATION
1. INSTALL CLUTCH DISC AND COVER ON FLY±WHEEL
(a) Insert SST in the clutch disc, and then set them and the cover
in position.
SST 09301±00110
(b) Align the matchmarks on the clutch cover and fly±wheel.
(c) Tighten the bolts evenly and gradually while pushing the SST.
Make several passes around the cover until it is snug.
(d) Torque the bolts on the clutch cover in the order shown.
Torque: 19 NVm (195 kgfVcm, 14 ftVlbf)
HINT: Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non±alignment:
0.5 mm (0.020 in.)
If alignment is not as specified, use the SST to adjust the dia-
phragm spring tip alignment.
SST 09333±00013
3. REMOVE CLUTCH COVER AND CLUTCH DISC
4. INSTALL CLUTCH RELEASE FORK
(a) Install the wave washer and pin to release fork.
(b) Install a new E±ring.
5. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to these parts:
wRelease fork and hub contact point
wRelease fork and push rod contact point
wRelease fork pivot point
± CLUTCHCLUTCH UNIT (2JZ±GTE)CL±15