TOYOTA AVENSIS 2003 Service Repair Manual

D30815
(b)(a)
D26903
D26902
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±39
AVENSIS REPAIR MANUAL (RM1018E)
58. CONNECT WIRE HARNESS
(a) Install the ground cable with bolt.
Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
(b) Install the air tube with bolt. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
59. INSTALL STARTER ASSY
(a) Connect the starter connector.
(b) Install the starter assy to the transaxle with the 2 bolts. Torque: 37 N
m (380 kgf
cm, 27 ft
lbf)
(c) Install the starter wire to starter assy with the nut. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
60. CONNECT RADIATOR RESERVE TANK ASSY
(a) Install the radiator reserve tank assy with the 2 bolts. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
61.INSTALL AIR TUBE NO.1 (See page 14±286)
62. INSTALL BATTERY TRAY
63. INSTALL BATTERY
64. 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)
65. INSTALL AIR CLEANER ASSY
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
66. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
67.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
68.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
69.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
70.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
71. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
72. STEERING WHEEL CENTER POINT
73. INSTALL ENGINE ROOM COVER SIDE
74. INSTALL RADIATOR SUPPORT OPENING COVER
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41±40
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
75. INSTALL HOOD SUB±ASSY Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
76.INSPECT HOOD SUB±ASSY (See page 75±2)
77.ADJUST HOOD SUB±ASSY (See page 75±2)
78.ADD TRANSAXLE OIL (See page 41±5)
79.INSPECT TRANSAXLE OIL (See page 41±2)
80. ADD POWER STEERING FLUID
81.BLEED POWER STEERING FLUID (See page 51±4)
82.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
83.INSPECT FLUID LEAK (See page 51±4)
84. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
85.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
86. INSTALL ENGINE UNDER COVER RH
87. INSTALL ENGINE UNDER COVER LH
88. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
89.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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410DS±01
D30478
Battery Clamp Sub±assyBattery Tray
Charcoal Canister Assy
Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2 Starter Assy Back±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
Clip
Clip
37 (380, 27)
Starter Connector
Transverse Engine
Engine Mounting Insulator
52 (530, 38)
52 (530, 38)
Ground Cable


Gasket
7.0 (71, 62 in.
lbf)
Filler Plug
37 (380, 27)
23 (230, 17)
47 (479, 35)
N´m (kgf´cm, ft´lbf) : Specified torque
19 (195, 14)
13 (130, 9)
64 (653, 47)
64 (653, 47)
5.0 (51, 44 in.
lbf)

Non±reusable part
5.0 (51, 44 in.
lbf)
14 (141, 10)
13 (133, 10)
13 (131, 9)
5.0 (51, 44 in.
lbf)
26 (260, 19)
25 (255, 18)
80 (816, 59)
26 (260, 19)
23 (230, 17)
Engine Room Cover Side
Radiator Support Opening Cover
40 (410, 30)
39 (400, 29)
Manual Transaxle Assy
64 (653, 47)
Battery
Clutch Release Cylinder Assy
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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D30479
Front Drive Shaft Assy RH

Snap Ring
Front Drive

Snap Ring
Transverse Engine
Engine Mounting Bracket Transverse Engine
Engine Mounting Insulator
64 (653, 47)
87 (887, 64)Transverse Engine
Engine Mounting Bracket


Cotter Pin
64 (653, 47)
52 (530, 38)

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)
29 (296, 21)
49 (500, 36)
74 (755, 55)
89 (908, 66)
8.0 (82, 71 in.
lbf)
133 (1,356, 83)
89 (908, 66)
41±14
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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4100Z±05
D25304
0 to 5 mm
(0 to 0.20 in.)
41±2
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE OIL (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE OIL (MTM)
ON±VEHICLE INSPECTION
1. INSPECT TRANSAXLE OIL
(a) Stop the vehicle on the level place.
(b) Remove the transmission filler plug and gasket.
(c) Check that the oil surface is within 5 mm (0.20 in.) from the lowest position of the inner surface of the transmission fill-
er plug opening.
NOTICE:

Excessively large or small amount of oil may cause
troubles.

After replacing oil, drive the vehicle and check the oil
level.
(d) Check for oil leakage when the oil level is low.
(e) Install the transmission filler plug and new gasket. Torque:
C50, C250: 39 N
m (400 kgf
cm, 29 ft
lbf)
E354, E357: 49 N
m (500 kgf
cm, 36 ft
lbf)
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4100Y±05
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM (MTM)
41±1
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.

: (C50 MANUAL TRANSAXLE Repair Manual Pub. No. 826E or C250 MANUAL TRANS\
AXLE Repair
Manual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E\
)
SymptomSuspect AreaSee page
Noise
6. Oil (Level low)
7. Oil (Wrong) C50/C250
E354/E357
8. Gear (Worn or damaged)
9. Bearing (Worn or damaged)41±2
41±3
41±5



Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged) C50/ C250 E354/E357
4. O±Ring (Worn or damaged)41±2


41±3
41±5

Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)41±7




Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)







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4105R±02
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
D30070
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±7
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION CONTROL CABLE ASSY (MTM)
REPLACEMENT
HINT:
COMPONENTS: See page 41±10
1.REMOVE AIR CONDITIONER UNIT ASSY (See page 55±55)
HINT:
Refer to the instructions for removal of the instrument panel sub±ass\
y lower.
2. REMOVE EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Remove the 3 nuts and heat insulator No.1.
4. REMOVE 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.
(c) Remove the 2 nuts, separate the control cable assy.
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D30071
D26893
D26895
D30071
D26972
41±8
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove the 2 bolts, separate the control cable assy.
(e) Remove the 2 clips, separate the cable ends of the control cable assy.
(f) Release the claws, remove the control cable assy.
5. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Put the control cable assy through the floor hole.
(b) Install the control cable assy with the 2 bolts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(c) Connect the control cable assy to the shift lever assy.
NOTICE:
Make sure that the claws are firmly engaged.
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D26894
Serrate Part
D30070
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±9
AVENSIS REPAIR MANUAL (RM1018E)
(d) Connect the end of the select cable to the shift lever assy
and install the clip.
NOTICE:

The serrate part of the select cable point should face
upward when the select cable point is connected.

The clip should be inserted to the direction as shown
in the illustration.
(e) Connect the end of the shift cable to the shift lever assy.
(f) Connect the control cable assy with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(g) Connect the 2 cable ends, install the 2 clips.
(h) Install the 2 clips to the control cable bracket.
6. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Install the heat insulator No.1 with the 3 nuts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
7. INSTALL EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
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4202Z±03
D30812
Clutch Accumulator Assy
Clutch Line
Wire Harness Clamp
N
m (kgf
cm, ft
lbf) : Specified torque Clutch Release Cylinder
Clutch Line
12 (120, 9)15 (155, 11)
15 (155, 11)
12 (120, 9)
Clutch Line
15 (155, 11)
±
CLUTCH CLUTCH ACCUMULATOR ASSY (1CD±FTV)
42±21
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH ACCUMULATOR ASSY (1CD±FTV)
COMPONENTS
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