TOYOTA AVENSIS 2002 Repair Manual

4202Z±03
D30812
Clutch Accumulator Assy
Clutch Line
Wire Harness Clamp
N
m (kgf
cm, ft
lbf) : Specified torqueClutch Release Cylinder
Clutch Line
12 (120, 9)15 (155, 11)
15 (155, 11)
12 (120, 9)
Clutch Line
15 (155, 11)
± CLUTCHCLUTCH ACCUMULATOR ASSY (1CD±FTV)
42±21
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH ACCUMULATOR ASSY (1CD±FTV)
COMPONENTS

4206G±01
D30813
(a)
(a) (b)(b)
(a)
(b)
D30813
(a)
(a) (b)(b)
(a)
(b)
D26852
SST(s)
42±22
±
CLUTCH CLUTCH ACCUMULATOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE BATTERY
2.REMOVE AIR TUBE NO.1 (See page 14±286) 3. REMOVE CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), disconnect the flexible hose tube.SST 09023±00100
HINT:
Use a container to catch the fluid.
(b) Remove a bolt, 2 nuts and clutch accumulator assy.
4. INSTALL CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), connect the 2 flexible hose tubes to the clutch accumulator assy.
SST 09023±00100
(b) Install the clutch accumulator assy with the 2 nuts and a
bolt.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
(c) Using SST(s), tighten the flexible hose tube. SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
5.INSTALL AIR TUBE NO.1 (See page 14±286)
6. INSTALL BATTERY
7. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the brake fluid and bleed clutch syst\
em. Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
8. CHECK CLUTCH FLUID LEAKAGE

4202V±03
D30477
LHD Steering Position Type:
RHD Steering PositionType:Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Gasket
Clip
Clutch Master Cylinder Assy
Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Clutch Master Cylinder AssyClip
Gasket
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

12 (120, 9)
12 (120, 9)
15 (155, 11)
15 (155, 11)
MP grease
42±12
± CLUTCHCLUTCH MASTER CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH MASTER CYLINDER ASSY (MTM)
COMPONENTS

4206E±01
D30068
D30069
SST(s)
D30782
RHD Steering Position Type:
LHD Steering Position Type:
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
42±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DRAIN CLUTCH FLUID
2. REMOVE BRAKE MASTER CYLINDER SUB±ASSY (LHD STEERING POSITION TYPE)
(See page 32±13)
3.REMOVE BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 32±19)
4. DISCONNECT CLUTCH RESERVOIR TUBE
(a) Loosen the clip and disconnect the clutch reservoir tubefrom the clutch master cylinder assy.
HINT:
Use a container to catch the fluid.
5. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST(s), disconnect the flexible hose tube. SST 09023±00100
HINT:
Use a container to catch the fluid.
6. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS W/HOLE PIN
(a) Remove the clip and hole pin.

D30782
RHD Steering Position Type:
LHD Steering Position Type:
MP Grease
D30069
SST(s)
D30068
Blue Mark
42±14
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE CLUTCH MASTER CYLINDER ASSY
(a) Remove the 2 nuts clutch master cylinder assy and gasket.
8. INSTALL CLUTCH MASTER CYLINDER ASSY
(a) Install the clutch master cylinder assy and gasket with the 2 nuts. Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
9. 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 assy 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.
10. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST(s), connect the flexible hose tube. SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
11. CONNECT CLUTCH RESERVOIR TUBE
(a) Connect the clutch reservoir tube with the clip to the clutch master cylinder assy.
NOTICE:
Connect the clutch reservoir tube so as not be twisted.
12.INSTALL BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 32±19)
13. INSTALL BRAKE MASTER CYLINDER SUB±ASSY (LHD STEERING POSITION TYPE) (See page 32±13)
14.BLEED BRAKE LINE (LHD STEERING POSITION TYPE) (See page 32±4)

±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
42±15
AVENSIS REPAIR MANUAL (RM1018E)
15. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the clutch fluid and bleed clutch sys\
tem.
Torque: 8.4 N
m (85 kgf
cm, 73 in.
lbf)
16. CHECK AND ADJUST BRAKE PEDAL HEIGHT (LHD STEERING POSITION TYPE) (See page 32±6)
17.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (See page 42±2)
18. CHECK BRAKE FLUID LEAKAGE (LHD STEERING POSITION TYPE)
19. CHECK CLUTCH FLUID LEAKAGE
20. CHECK FLUID LEVEL IN RESERVOIR

4200D±04
D30053
LHD Steering Position Type:
Pedal Height Adjust Point
Push Rod
Play and
Free Play
Adjust
PointPush Rod
Play
Pedal Height
RHD Steering Position Type:
Push Rod Play and
Free Play Adjust Point
Pedal Height
Adjust Point
Push Rod
Play
Pedal Height
42±2
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH PEDAL SUB±ASSY (MTM)
ADJUSTMENT
1. INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY
(a) Turn over the floor carpet.
(b) Check that the pedal height is correct.
Pedal height from asphalt sheet:
LHD Steering Position Type:
1CD±FTV Engine Type
154.0 to 164.0 mm (6.063 to 6.457 in.)
Others:
139.6 to 149.6 mm (5.496 to 5.890 in.)
RHD Steering Position Type:
1CD±FTV Engine Type
158.4 to 168.4 mm (6.236 to 6.630 in.)
Others:
148.4 to 158.4 mm (5.843 to 6.236 in.)
(c) Adjust the pedal height.
(1) Loosen the lock nut and turn the stopper bolt until
the height is correct. Tighten the lock nut.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
(d) Check that the pedal free play and push rod play are cor-
rect.
(1) Depress the pedal until clutch resistance is felt.
Pedal free play: 5.0 to 15.0 mm (0.197 to 0591 in.)
(2) Gently depress the pedal until the resistance begins
to increase a little.
Push rod play at pedal top:
1.0 to 5.0 mm (0.039 to 0.197 in.)

CL0102Pedal Free Play
CL0512
25 mm (0.98 in.) or more
Release Point
Full Stroke
End Position
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
42±3
AVENSIS REPAIR MANUAL (RM1018E)
(e) Adjust the pedal free play and push rod play.
(1) Loosen the lock nut and turn the push rod until the
free play and push rod play are correct.
(2) Tighten the lock nut.
(3) After adjusting the pedal free play, check the pedal
height.
(4) Connect the air duct and install the lower finish pan-
el.
(f) Check the clutch release point.
(1) Pull the parking brake lever and install wheel stop-
per.
(2) Start the engine and idle.
(3) Without depressing the clutch pedal, slowly adjust
the shift lever to the reverse position until the gears
contact.
(4) Gradually depress the clutch pedal and measure
the stroke distance from the point that the gear
noise stops (release point) up to the full stroke end
position.
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following opera-
tions.

Check pedal height.

Check push rod play and pedal free play.

Bleed the clutch line.

Check the clutch cover assy and disc assy.

4202T±02
D30054
LHD Steering Position Type:
w/o Turn Over:
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Clutch Pedal Bush
Clutch Master
Cylinder Push Rod
Clevis Bush
Clutch Pedal
Pad Clutch Pedal Bush
Clutch Pedal Sub±assy Clutch Pedal Support Sub±assyClip
19 (195, 14)
37 (375, 27)
12 (120, 9)
w/ Turn Over:
Turn Over Spring
Seat Compression Spring
MP Grease
N
m (kgf
cm, ft
lbf) : Specified torqueClutch Pedal Turn Over Bush
Clutch Pedal No.1 Cushion
19 (195, 14)
Clutch Master Cylinder
Push Rod Clevis w/ Hole PinClip
37 (375, 27)
Clutch Pedal Support Sub±assy12 (120, 9)

Clutch Pedal Bush
Clutch Pedal Sub±assy
Clutch Master
Cylinder Push Rod
Clevis Bush


Clutch Pedal
Pad
Clutch Pedal No.1 Cushion

Non±reusable partBush Clutch Pedal
Clutch Pedal Spring 1CD±FTV Engine Type:
Clutch Pedal Spring
Clutch Start Switch Assy
16 (160, 12)
Clutch Pedal Turn Over Bush
42±4
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

D30304
RHD Power Steering Type:
w/o Turn Over:
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Clutch Pedal SpringClutch Pedal Bush
Clutch Master
Cylinder Push Rod
Clevis Bush
Clutch Pedal
Pad Clutch Pedal Bush
Clutch Pedal Sub±assy Clip
19 (195, 14)
37 (375, 27)
12 (120, 9)
Clutch Pedal No.1 Cushion
w/ Turn Over:
MP Grease
N
m (kgf
cm, ft
lbf) : Specified torque
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Clip
37 (375, 27)
Turn Over Spring
Seat Compression Spring
Clutch Pedal Support Sub±assy
Clutch Master
Cylinder Push Rod
Clevis Bush
Clutch Pedal No.1 Cushion
Clutch Pedal
Pad Clutch Pedal No.1 CushionClutch Pedal Sub±assyClutch Pedal
Turn Over Bush
19 (195, 14)

Non±reusable part
Clutch Pedal Bush
Clutch Pedal Bush Clutch Pedal Support Sub±assy
1CD±FTV Engine Type:
Clutch Pedal Spring
19 (195, 14)
Clutch Pedal Turn Over Bush
19 (195, 14)Clutch Start Switch Assy
12 (120, 9)
Clutch Pedal No.1 Cushion
16 (160, 12)
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
42±5
AVENSIS REPAIR MANUAL (RM1018E)