TOYOTA AVENSIS 2003 Service Repair Manual

D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±4
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 9.9
0.3 mm (0.390
0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
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41046±12
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
41±5
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (E354/E357)
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
6.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
7. REMOVE FRONT TRANSAXLE CASE COVER OILSEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
8. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
9. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal.
SST 09608±10010, 09950±70010 (09951±07200)
Drive in depth: 0
0.5 mm (0
0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.
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D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±6
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09608±32010, 09950±70010 (09951±07200)
Drive in depth: 3.5
0.5 mm (0.138
0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts)
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
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410DT±01
D30082
13 (133, 10)Hood Sub±assy
Engine Cover Sub±assy No.1
Air Cleaner Assy
BatteryBattery Tray
Clip
Clip
Clip
Starter Assy
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
12 (120, 9)
Manual Transaxle Assy
46 (469, 34)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.

lbf)
Engine Room Cover Side
Radiator Support Opening Cover
44 (449, 32)
44 (449, 32)
Clutch Release Cylinder Assy
Starter
Connector
37 (380, 27)
13 (130, 9)
46 (469, 34)
8.4 (85, 74 in.
lbf)
46 (469, 34)
Transmission Control Cable Assy
Battery Clamp Sub±assy
5.0 (51, 44 in.
lbf)
9.0 (92, 80 in.
lbf)
Back±up Lamp Switch Connector
5.0 (51, 44 in.
lbf)
Clip
26 (260, 19)
40 (410, 30)
64 (653, 47)
52 (530, 38)
13 (131, 9)
41±22
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS
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D30473
Front Drive Shaft Assy RH
Snap Ring
Transverse Engine
Engine Mounting Insulator
64 (653, 47)
87 (887, 64)

Cotter Pin
64 (653, 47)

Cotter Pin
Engine Under Cover RH

Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque
64 (653, 47)

216 (2,203, 159)45 (459, 33)
Engine Under Cover LH
35 (360, 26)
74 (755, 55)
52 (530, 38)
49 (500, 36)
133 (1,356, 83)
49 (500, 36)
89 (908, 66)
Transverse Engine
Engine Mounting Bracket
133 (1,356, 83)
52 (530, 38)89 (908, 66)
29 (296, 21)Transverse Engine
Engine Mounting Insulator
Transverse Engine
Engine Mounting Bracket
8.0 (82, 71 in.
lbf)
74 (755, 55)
Front Drive Shaft Assy LH
64 (650, 47)
64 (650, 47)
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
41±23
AVENSIS REPAIR MANUAL (RM1018E)
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410DU±01
D30480
D30081
41±24
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER SUB±ASSY NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19.REMOVE STARTER ASSY (See page 19±12) 20. SEPARATE WIRE HARNESS
(a) Remove the 3 bolts, and separate the 3 wire harnesses.
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D30066
D30064
G24413
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
41±25
AVENSIS REPAIR MANUAL (RM1018E)
21. SEPARATE CONNECTOR
(a) Separate the back±up lamp switch connector.
22. SEPARATE CLUTCH RELEASE CYLINDER ASSY
(a) Remove the 3 bolts and separate the release cylinder.
23. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the 2 cables from the trans-
axle.
(b) Remove the 2 clips, separate the 2 cables from the brack- et.
24.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
25.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
26. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
27.DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51±36) SST 09023±12700
28.DISCONNECT PRESSURE FEED TUBE ASSY (See page 51±36)
SST 09023±12700
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D25745
No.1 Engine Hanger No.2 Engine Hanger
D30067
D30077
D25747
41±26
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
29. SUSPEND ENGINE ASSY
(a) Install the No.1 and No.2 engine hangers in the correct direction.
Parts No.:
No. 1 engine hanger: 12281±28010
No. 2 engine hanger: 12282±28010
Bolt: 91512±61020
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Attach the engine chain hoist to the engine hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
30.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26)
31. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the manual transaxle with a transmission jack. 32. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator LH.
33. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket.
34. REMOVE MANUAL TRANSAXLE ASSY
(a) Separate the wire harness clamp.
(b) Remove the 10 bolts.
(c) Separate and remove the transaxle from the engine.
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D30076
D30078
D30079
D30079
(a)
(a)
(a)
(b)
D30078
(a)
(b)
(b)
(a)
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
41±27
AVENSIS REPAIR MANUAL (RM1018E)
35. REMOVE MANUAL TRANSMISSION CASE
PROTECTOR
(a) Remove the 2 bolts and case protector.
36. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket.
(b) Remove the 2 bolts and engine mounting bracket FR from the transaxle.
37. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR from the engine mounting bracket.
(b) Remove the 3 bolts and engine mounting bracket RR
from the transaxle.
38. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket RR and 3 bolts to the transaxle.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
(b) Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
39. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
transaxle.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
(b) Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
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D30076
D25747
AB
C
BA
D30077
D30067
A
A
A
A
B
41±28
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
40. INSTALL MANUAL TRANSMISSION CASE PROTECTOR
(a) Install the case protector with the 2 bolts.
Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
41. INSTALL MANUAL TRANSAXLE ASSY
(a) Align the input shaft with the clutch disc and install the transaxle to the engine.
(b) Install the 10 bolts. Torque:
Bolt A: 64 N
m (653 kgf
cm, 47 ft
lbf)
Bolt B: 46 N
m (469 kgf
cm, 34 ft
lbf)
Bolt C: 44 N
m (449 kgf
cm, 32 ft
lbf)
(c) Connect the wire harness clamp.
42. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket LH to the transaxle with the 3 bolt.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
43. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Install the engine mounting insulator LH with the 5 bolts and nut.
Torque:
Bolt A: 52 N
m (530 kgf
cm, 38 ft
lbf)
Bolt B: 80 N
m (816 kgf
cm, 59 ft
lbf)
44.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26) SST 09670±00010
45.CONNECT PRESSURE FEED TUBE ASSY (See page 51±36)
SST 09023±12700
46.CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51±36) SST 09023±12700
47. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
48.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
49.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
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