TOYOTA AVENSIS 2002 Repair Manual

4206D±01
D30782
RHD Steering Position Type:
LHD Steering Position Type:
D26300
LHD Steering
Position Type:RHD Steering
Position Type:
42±6
±
CLUTCH CLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE INSTRUMENT PANEL SUB±ASSY LOWER (LHD STEERING POSITION TYPE) (See page 71±11)
2.REMOVE COMBINATION METER ASSY (RHD STEERING POSITION TYPE) (See page 71±21)
3. REMOVE CLUTCH PEDAL SPRING
4. REMOVE CLUTCH MASTER CYLINDER PUSH RODCLEVIS W/HOLE PIN
(a) Remove the clip and hole pin.
5. REMOVE CLUTCH PEDAL SUPPORT SUB±ASSY
(a) LHD steering position type: Remove the 2 nuts, bolt and clutch pedal support assy.
(b) RHD steering position type:
Remove the 2 bolts, 2 nuts and clutch pedal support assy.

D30775
D30776
D30781
D30780
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
42±7
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE TURN OVER SPRING SEAT COMPRESSION
SPRING (W/ TURN OVER)
(a) Mount the clutch pedal in a soft jaw vise.
(b) Using a screwdriver, remove the spring.
7. REMOVE CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
8. REMOVE CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
(a) Using a 8 mm hexagon wrench and a hammer, remove
the turn over bush.
9. REMOVE CLUTCH PEDAL SUB±ASSY
(a) Remove the bolt and nut.
(b) Remove the clutch pedal from the clutch pedal support.
10. REMOVE CLUTCH PEDAL PAD
11. REMOVE CLUTCH PEDAL BUSH
(a) Remove the 2 bushes from the clutch pedal.

D30779
LHD Steering Position Type:
RHD Steering Position Type:
D30777
D30778MP Grease 42±8
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE CLUTCH PEDAL NO.1 CUSHION
(a) LHD steering position type:
Using needle±nose pliers, remove the No.1 cushion from
the clutch pedal.
(b) RHD steering position type:
Using needle±nose pliers, remove the 2 No.1 cushions
from the clutch pedal.
13. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS BUSH
(a) Using a 8 mm hexagon wrench and a hammer, remove
the clevis bush from the clutch pedal.
14. INSTALL CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS BUSH
(a) Apply MP grease to the inside of a new clevis bush.
(b) Install the clevis bush to the clutch pedal.
HINT:
Install the clevis bush from the right side of the vehicle.

D30779
LHD Steering Position Type:
RHD Steering Position Type:
D30780MP Grease
D30781
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
42±9
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL CLUTCH PEDAL NO.1 CUSHION
(a) LHD steering position type:
Using needle±nose pliers, install the No.1 cushion to the
clutch pedal.
(b) RHD steering position type:
Using needle±nose pliers, install the 2 No.1 cushions to
the clutch pedal.
16. INSTALL CLUTCH PEDAL BUSH
(a) Apply MP grease to the inner, outer and end surface of 2
new bushes.
(b) Install the 2 bushes to the clutch pedal.
17. INSTALL CLUTCH PEDAL PAD
18. INSTALL CLUTCH PEDAL SUB±ASSY
(a) Install the clutch pedal to the clutch pedal support with the
bolt and nut.
Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)
HINT:
Install the bolt from the right side of the vehicle.

D30783MP Grease
D30775MP Grease
D26300
LHD Steering
Position Type:RHD Steering
Position Type: 42±10
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
19. INSTALL CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
(a) Apply MP grease to the inside of the turn over bush.
(b) Install the turn over bush to the clutch pedal support.
20. INSTALL CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
(a) Apply MP grease to the inside of the turn over bush.
(b) Install the turn over bush to the clutch pedal.
21. INSTALL TURN OVER SPRING SEAT COMPRESSION
SPRING (W/ TURN OVER)
(a) Apply MP grease to the contact surface of the bush and
spring.
(b) Install the spring to the clutch pedal and clutch pedal sup-
port.
22. INSTALL CLUTCH PEDAL SUPPORT SUB±ASSY
(a) LHD steering position type:
Install the clutch pedal support to the vehicle with the 2
nuts and bolt.
Torque:
Bolt: 19 N
m (195 kgf
cm, 14 ft
lbf)
Nut: 12 N
m (120 kgf
cm, 9 ft
lbf)
(b) RHD steering position type:
Install the clutch pedal support to the vehicle with the 2
bolts and 2 nuts.
Torque:
Bolt: 19 N
m (195 kgf
cm, 14 ft
lbf)
Nut: 12 N
m (120 kgf
cm, 9 ft
lbf)

D30782
LHD Steering Position Type:
RHD Steering Position Type:MP Grease
±
CLUTCH CLUTCH PEDAL SUB±ASSY (MTM)
42±11
AVENSIS REPAIR MANUAL (RM1018E)
23. INSTALL CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS W/HOLE PIN
(a) Apply MP grease to the contact surface of the hole pin
and clevis bush.
(b) Connect the clevis to the clutch pedal with the hole pin.
HINT:

RHD steering position type:
Install the hole pin from the right side of the vehicle.

LHD steering position type:
Install the hole pin from the left side of the vehicle.
(c) Install the clip to the hole pin.
24. INSTALL CLUTCH PEDAL SPRING
25.INSTALL COMBINATION METER ASSY (RHD STEERING POSITION TYPE) (See page 71±21)
26. INSTALL INSTRUMENT PANEL SUB±ASSY LOWER (LHD STEERING POSITION TYPE) (See page 71±11)
27.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (See page 42±2)

4202X±03
D30055Lithium soap glycol grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part 1CD±FTV Engine Type:
Bleeder PlugRelease Cylinder Body
Piston
Push RodBoot Bleeder Plug
Cap
8.4 (85, 74 in.
lbf)
Wire Harness ClampClutch Accumulator Assy
Spring
1AZ±FSE/1AZ±FE Engine Type:
15 (155, 11)
12 (120, 9)


12 (120, 9)
Release Cylinder Body
12 (120, 9)
Release Cylinder Body
Clutch Line Clamp
Clutch Line Bracket
15 (155, 11)
12 (122, 9)
5.0 (51, 44 in.
lbf)1ZZ±FE/3ZZ±FE Engine Type:
15 (155, 11)Clutch Line Clamp
14 (141, 10)
15 (155, 11)
12 (120, 9)
42±16
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH RELEASE CYLINDER ASSY (MTM)
COMPONENTS

4206F±01
D30487
SST(s)
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:SST(s)
D30814
±
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)
42±17
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
1. REMOVE BATTERY (1CD±FTV ENGINE TYPE)
2.REMOVE AIR TUBE NO.1 (1CD±FTV ENGINE TYPE) (See page 14±286)
3. DISCONNECT CLUTCH RELEASE CYLINDER TOFLEXIBLE HOSE TUBE (EXCEPT 1CD±FTV ENGINE
TYPE)
(a) Using SST(s), disconnect the flexible hose tube. SST 09023±00100
HINT:
Use a container to catch the fluid.
4. REMOVE CLUTCH ACCUMULATOR ASSY (1CD±FTV ENGINE TYPE)
(a) Disconnect the wire harness clamp.
(b) Using SST(s), disconnect the 2 flexible hose tubes. SST 09023±00100
HINT:
Use a container to catch the fluid.
(c) Remove the 2 nuts, bolt and clutch accumulator assy.

D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:
D26804
42±18
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE CLUTCH RELEASE CYLINDER ASSY
(EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type:
Remove the 3 bolts, clutch release cylinder assy, and
clutch line bracket.
(b) 1AZ±FE/1AZ±FSE Engine Type:
Remove the 3 bolts and clutch release cylinder assy.
6. REMOVE CLUTCH RELEASE CYLINDER ASSY
(1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, remove the 2 bolts
and clutch release cylinder assy.
7. REMOVE CLUTCH RELEASE CYLINDER KIT
(a) Remove the boot from the cylinder body.
(b) Remove the push rod from the cylinder body.
(c) Remove the piston from the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(d) Remove the spring from the cylinder body.
(e) Remove the bleeder plug cap from the bleeder plug.
8. REMOVE RELEASE CYLINDER BLEEDER PLUG
9. INSTALL RELEASE CYLINDER BLEEDER PLUG
Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)

CL0672
D26804
D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:(1)
(1)
(1)
(1)
(2) (2)
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
42±19
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL CLUTCH RELEASE CYLINDER KIT
(a) Install the bleeder plug cap to the bleeder plug.
(b) Install a new spring to the cylinder body.
(c) Coat the parts with lithium soap base glycol grease, as
shown in the illustration.
(d) Install the piston to the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(e) Install the push rod to the cylinder body.
(f) Install the boot to the cylinder body.
11. INSTALL CLUTCH RELEASE CYLINDER ASSY
(1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, install the clutch re-
lease cylinder assy with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
12. INSTALL CLUTCH RELEASE CYLINDER ASSY
(EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type:
(1) Install the clutch release cylinder and clutch line
bracket with the 2 bolts.
Torque: 14 N
m (141 kgf
cm, 10 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(b) 1AZ±FE/1AZ±FSE Engine Type:
(1) Install the clutch release cylinder with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)