Toyota Aygo service bulletin

Clutch kits from Blue Print

Published:  08 May, 2014

There are more than 830 part numbers in Blue Print's clutch kit programme, covering nearly 2,200 Asian and American applications. Clutch cables, hoses, master cylinders and slave cylinders are also provided. Clutch kits are covered by a three-year, unlimited mileage warranty against manufacturing defects. The firm keeps a close eye on vehicle recalls and service bulletins and one part that has been identified to fail prematurely is the clutch on the 1.0 Toyota Aygo, which also fits the Peugeot 107 and Citroen C1. Drivers began to complain about clutch slip and noise, a funny smell and a total failure of the OE clutch at around 40,000 miles. Toyota issued a bulletin saying that all clutch replacements should be conducted using a larger clutch assembly, replacing the original 180mm clutch with a larger 190mm unit, which can be sourced as a kit from Blue Print. A further bulletin from Toyota stated this would not solve the whole problem and that clutch pedal free play must be checked and adjusted at every 9,000 mile service interval as the amount of free play in the pedal reduces, so does the amount of pressure applied by the clutch cover, which speeds up wear.

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    Blue Print's engine management range has nearly 1,050 part numbers for around 5,500 applications and includes camshaft position sensors, knock sensors, MAP sensors, oxygen sensors and many more. New additions include a camshaft position sensor for the Suzuki Jimny, Swift and Wagon, a throttle body for the Daewoo and Chevrolet Matiz, a knock sensor for the Toyota Auris, Prius, Yaris and other models as well as a crankshaft angle sensor for the Kia Rio 1.3i.

  • Three tools in one 

    The G-Scan 2 is available through official distributor Blue Print and boasts the same extensive coverage for Asian vehicles as the two existing G-Scan kits, including being OEM for Hyundai and Kia, a two-year warranty and two years of free software updates but it has some valuable new additions. The tool has a built-in 2/4 channel oscilloscope and digital multimeter to identify fault codes, measure voltage or amperage fluctuations of sensors or actuator circuits and it also measures resistance, frequency, duty cycle and pulse width. When working on Hyundai and Kia vehicles, you can view data from the scope alongside the DTC data, easily switching between the three functions without the need to look at data on a laptop. It is larger than its predecessors with a high definition 7" screen and has four times the capacity with a 16GB memory card. It powers up faster using a triple CPU and has an intuitive layout and menu system which is navigated by touchscreen or the 12-button menu system. New software features include a communication line inspection, unit converter and special functions calculator. Wi-Fi is built in so can be updated remotely and you can print directly to a Wi-Fi enabled printer and view graphs and data on a PC without a cable connection.

  • Restricted flow will cause a whine 

    A power steering reservoir for the Chrysler Grand Voyager 3.3i 2001 to 2006 and Voyager 3.3i 2001 to 2004 is available from Blue Print. When this filter becomes contaminated and partially blocked, flow is restricted and this usually results in an abnormal whine from the power steering pump which tends to be worse from a cold start-up and at slow speeds. As long as the pump hasn't been starved of fluid for too long, the problem can be fixed with a replacement reservoir which has a new filter and the addition ofsome fresh fluid. Before fitting this direct replacement part, the firm advises that you drain as much of the original fluid from the system as possible before filling with fluid of the correct specification.

  • Check your strut 

    A few years ago, Blue Print introduced a short range of gas struts as a result of customers reporting on high failure applications. The range has grown to nearly 170 references, covering 600 popular UK applications. Key newbies include a gas strut tail gate for the Nissan Pathfinder 2.5/3.0 DT and the Toyota Avensis 1.8i, 2.0DT and 2.0i. Gas struts are used in boot lids, glass openings and some vehicle's bonnets and lose their effectiveness over time, eventually resulting in failure. So check those struts and remember to replace them in pairs.

  • Calipers and cables 

    There are over 8,000 part numbers for over 28,000 applications in Blue Print's braking range, all covered by a three-year unlimited mileage warranty. Included in the programme are ABS sensors and reluctor rings, caliper repair kits, master cylinders, brake pad wear indicators, cables, discs, pads, shoes and more. New references include an ABS sensor for the Honda Civic 2006>2012 and Nissan Qashqai 2006>2014, front and rear brake pads for the Toyota Proace 2013> and a rear brake drum for the Vauxhall Agila 2000> 2007.


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