TOYOTA AVENSIS 2003 Service Repair Manual

G24413
D30064
A
B
D30066
D30081
B
C
A
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
41±29
AVENSIS REPAIR MANUAL (RM1018E)
50. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Connect the 2 cable ends, install the 2 clips.
(b) Install the 2 clips to the control cable bracket.
51. INSTALL CLUTCH RELEASE CYLINDER ASSY
(a) Install the release cylinder with the 3 bolts.
Torque:
Bolt A: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
Bolt B: 12 N
m (120 kgf
cm, 9 ft
lbf)
52. CONNECT CONNECTOR
(a) Connect the back±up lamp switch connector.
53. CONNECT WIRE HARNESS
(a) Install the 3 wire harnesses with the 3 bolts. Torque:
Bolt A: 26 N
m (260 kgf
cm, 19 ft
lbf)
Bolt B: 8.4 N
m (85 kgf
cm, 74 in.
lbf)
Bolt C: 40 N
m (410 kgf
cm, 30 ft
lbf)
54.INSTALL STARTER ASSY (See page 19±12)
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D30080
41±30
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts. Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Nut: 3.5 N
m (36 kgf
cm, 31 in.
lbf)
59. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
60. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUB±ASSY Torque: 13 N
m (132 kgf
cm, 10 ft
lbf)
64.INSPECT HOOD SUB±ASSY (See page 75±2)
65.ADJUST HOOD SUB±ASSY (See page 75±2)
66.ADD TRANSAXLE OIL (See page 41±5)
67.INSPECT TRANSAXLE OIL (See page 41±2)
68. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
69.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
70.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page)See page 50±9)
71.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
72.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76.BLEED POWER STEERING FLUID (See page 51±4)
77.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
78.INSPECT FLUID LEAK (See page 51±4)
79.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
83.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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410DV±01
D30475
13 (133, 10)Hood Sub±assy
Radiator Reserve Tank Assy
Engine Cover No.1
5.0 (51, 44 in.
lbf)
7.0 (71, 62 in.
lbf)
Air Cleaner Assy
Battery Clamp
Sub±assy
3.5 (36, 31 in.
lbf)
Battery
Battery Tray
Clip
Clip
Clip
Floor Shift Transmission
Control Cable Assy
Starter Assy
Starter Connector
Ground Cable
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)
Manual Transmission
Case Protector
64 (653, 47)
40 (408, 30)
20 (200, 14)
8.0 (82, 71 in.
lbf)
40 (408, 30)
64 (653, 47)

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
12 (120, 9)
5.0 (51, 44 in.

lbf)
64 (653, 47)
Manual Transaxle Assy
13 (133, 10)
37 (380, 27)
46 (469, 34)
13 (130, 9)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.
lbf)
8.0 (82, 71 in.
lbf)
6.0 (61, 53 in.
lbf)
52 (530, 38)
25 (255, 18)
Air Tube No.1
25 (255, 18)
Engine Room Cover Side
Radiator Support
Opening Cover
Clip
13 (131, 9)
12 (120, 9)
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±31
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1CD±FTV)
COMPONENTS
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D30476
Front Drive Shaft Assy RHFront Drive Shaft Assy LH

Snap Ring
Transverse Engine
Engine Mounting Bracket
Transverse Engine
Engine Mounting
Transverse Engine
Engine Mounting Bracket
64 (653, 47)

Cotter Pin
52 (530, 38)

Cotter Pin
49 (500, 36)8.0 (82, 71 in.
lbf)

216 (2,203, 159)

Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque
Engine Under Cover RH
Engine Under Cover LH
Transverse Engine
Engine Mounting Bracket
64 (650, 47)
64 (650, 47)
64 (653, 47)
87 (887, 64)
64 (653, 47)
49 (500, 36)
133 (1,356, 83)
45 (459, 33)
29 (296, 21)
52 (530, 38)
74 (755, 55)
74 (755, 55)
89 (908, 66)
133 (1,356, 83)
52 (530, 38)
89 (908, 66)
35.3 (360, 26)
41±32
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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410DY±01
D26902
D26903
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±33
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 RH
8. REMOVE ENGINE UNDER COVER LH
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 NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18.REMOVE AIR TUBE NO.1 (See page 14±286)
19. SEPARATE RADIATOR RESERVE TANK ASSY
(a) Remove the 2 bolts, separate the radiator reserve tankassy.
20. REMOVE STARTER ASSY
(a) Remove the nut, disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.
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D30815
D26905
G24412
G24413
41±34
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
21. DISCONNECT WIRE HARNESS
(a) Remove the bolt, disconnect the ground cable.
(b) Remove the bolt, separate the air tube.
22. DISCONNECT CONNECTOR
(a) Disconnect the back±up lamp switch connector.
23.REMOVE CLUTCH ACCUMULATOR ASSY (See page 42±22) SST 09023±00100
24.REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 42±17) SST 09023±00100
25. SEPARATE ACCUMULATOR TO FLEXIBLE HOSETUBE
(a) Remove the 3 bolts, separate the flexible hose tube with brackets from the transaxle.
26. 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.
27.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
28.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
29. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
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A79193Engine Hanger No.1
Engine Hanger No.2
Engine Hanger No.1 UPR
D30072
D30073
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±35
AVENSIS REPAIR MANUAL (RM1018E)
30.DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51±36)
SST 09023±12700
31.DISCONNECT PRESSURE FEED TUBE ASSY (See page 51±36)
SST 09023±12700
32. SUSPEND ENGINE ASSY
(a) Install the 2 engine hangers with the 2 bolts.Parts No.:
No.1 engine hanger UPR (yellow) 12284±27020
No.1 engine hanger UPR (black) 12284±27030
No.1 engine hanger 12281±27050
No.2 engine hanger (yellow) 12282±27060
No.2 engine hanger (black) 12282±27070
Bolt: 91642±81025
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
(b) Attach the engine chain hoist to the hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
33.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26)
34. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the transaxle with a transmission jack.
35. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator LH from the body.
36. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from
the transaxle.
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D26918
D30076
D30074
D30075
D30075
(b)
(a)
(a)
(a)
41±36
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE MANUAL TRANSAXLE ASSY
(a) Remove the 8 bolts.
(b) Remove the transaxle from the engine.
38. REMOVE MANUAL TRANSMISSION CASE PROTECTOR
(a) Remove the 2 bolts and case protector.
39. 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.
40. 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.
41. 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.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
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D30074
(a)
(b)
(a)
(b)
D30076
D26918
AB
C D
E
D30073
D30072
A
A
A
A
B
A
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±37
AVENSIS REPAIR MANUAL (RM1018E)
42. 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.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
43. INSTALL MANUAL TRANSMISSION CASE PROTECTOR
(a) Install the case protector with the 2 bolts. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
44. INSTALL MANUAL TRANSAXLE ASSY
(a) Align the input shaft with the clutch disc and install the transaxle to the engine.
(b) Install the 8 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: 40 N
m (408 kgf
cm, 30 ft
lbf)
Bolt D: 20 N
m (200 kgf
cm, 14 ft
lbf)
Bolt E: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
45. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
46. 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)
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G24413
G24412
AB
D26905
41±38
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
47.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26) SST 09670±00010
48.CONNECT PRESSURE FEED TUBE ASSY (See page 51±36)
SST 09023±12700
49.CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51±36) SST 09023±12700
50. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
51.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
52.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6) 53. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Connect the 2 cable ends, install the 2 clips.
(b) Install the 2 clips to the control cable bracket.
54. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE
(a) Install the flexible hose tube with the 3 bolts.Torque:
Bolt A: 12 N
m (120 kgf
cm, 9 ft
lbf)
Bolt B: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Bolt C: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
55.INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 42±17) SST 09023±00100
56.INSTALL CLUTCH ACCUMULATOR ASSY (See page 42±22) SST 09023±00100
57. CONNECT CONNECTOR
(a) Connect the back±up lamp switch connector.
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