User: What is the process on changing the clutch
Assistant: Changing the clutch on a fourth-generation Toyota Celica (ST160, ST162, ST165) can be a challenging but rewarding task. Here’s a comprehensive step-by-step guide on how to do it, incorporating advice and common practices noted in the community discussions.
### Tools and Materials Needed:
– Basic hand tools (wrenches, sockets, ratchet)
– Torque wrench
– Clutch replacement kit (clutch disc, pressure plate, throw-out bearing)
– Flywheel (if needed)
– Engine hoist (optional for engine removal)
– Transmission jack (optional)
– Brake fluid (for clutch system)
– Engine oil (for any leaks checked during the process)
– Safety equipment (gloves, goggles)
– Service manual or BGB (for torque specs and detailed diagrams)
### Steps to Change the Clutch:
1. **Preparation:**
– Ensure your vehicle is on a flat surface and securely raised on jack stands.
– Disconnect the battery.
– Remove any necessary components in the way, such as the air intake, battery, or exhaust components.
2. **Choice of Method:**
– **Remove the Engine vs. Remove the Transmission:**
The easiest method often recommended is to remove the engine along with the transmission. This provides better access and makes it easier to see what you’re working with. Some opt to only remove the transmission, which may be a viable option but more difficult due to space constraints【4:2†source】【4:14†source】.
3. **Draining Fluids:**
– Drain the engine oil and transmission fluid to prevent spills during the removal process.
4. **Disconnecting Components:**
– Detach the driveshafts (if applicable).
– Disconnect the clutch cable or hydraulic lines from the clutch master and slave cylinders.
– Remove the starter motor if it interferes with extraction.
5. **Removing the Transmission/Engine:**
– If you’re removing the engine, carefully unbolt it from its mounts and any other connected components, then lift it out.
– For transmission removal, unbolt and slide it from the engine. You may need to support the transmission with a jack.
6. **Clutch Replacement:**
– Once you have access to the flywheel, inspect it for any damage or warping. If needed, have it resurfaced or replaced.
– Remove the pressure plate by unbolting it from the flywheel. The clutch disc will come off with it.
– Replace the throw-out bearing and lubricate the clutch fork and pivot ball with high-quality grease【4:0†source】【4:3†source】.
– Install the new clutch disc and pressure plate, ensuring proper alignment. Use a clutch alignment tool if available. Torque the pressure plate bolts to the specified settings in your service manual【4:1†source】.
7. **Reassembling:**
– Re-attach the transmission or engine by reversing the disassembly steps. Ensure all connectors are properly reattached, and double-check hydraulic lines for leaks【4:0†source】.
– If you removed the engine, reattach any components such as the exhaust, air intake, and other peripherals.
8. **Final Checks:**
– Before starting the car, ensure to refill the transmission with fluid and bleeding the clutch hydraulic system properly.
– Reconnect the battery and start the car to ensure everything operates smoothly. Test the clutch’s engagement and disengagement.
### Tips:
– It is often recommended to replace other components (like the rear main seal, clutch slave cylinder, and flywheel) while the engine is out for preventive maintenance【4:19†source】. This saves time and effort in the long run.
– Make sure to have a friend or assistant help, especially during the removal and reinstallation stages, as aligning the transmission can be tricky【4:1†source】【4:8†source】.
Changing a clutch can take time, especially if it’s your first time. Plan for potential delays, and don’t hesitate to consult your Toyota service manual for specific details on torque settings and diagrams. Good luck!
User: Where can I get a service manual
Assistant: You can obtain a service manual for the fourth-generation Toyota Celica (ST160, ST162, ST165) from several sources:
1. **Big Green Book (BGB) Online**: Websites like celicatech.com offer downloadable versions of the Big Green Book, which is the official Toyota service manual. However, you may need to be a member to access the downloads【4:6†source】.
2. **AllTrac Forum**: The AllTrac forum also has resources where users share links to service manuals for various Celica models, including the ST165. You can search for specific threads that might provide downloadable PDFs【4:2†source】【4:10†source】.
3. **eBay**: Many users have reported finding service manuals on eBay, often at reasonable prices. You might be able to find both new and used manuals there【4:8†source】【4:12†source】.
4. **Toyota Dealership or Toyota Publications**: For the most accurate and up-to-date manuals, consider contacting a Toyota dealership. They can often help you order a new service manual directly from Toyota【4:10†source】.
By exploring these avenues, you should be able to find the service manual you need for your Toyota Celica.