TOYOTA AVENSIS 2002 Repair Manual

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.

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)

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.

D26918
D30076
D30074
D30075
D30075
(b)
(a)
(a)
(a) 41±36
± MANUAL TRANSMISSION/TRANSAXLEMANUAL 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)

D30074
(a)
(b)
(a)
(b)
D30076
D26918
A
B
CD
E
D30073
D30072
A
A
A
A
B
A
± MANUAL TRANSMISSION/TRANSAXLEMANUAL 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)

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.

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

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)

410DS±01
D30478
Battery Clamp Sub±assy
Battery Tray
Charcoal Canister Assy Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2
Starter AssyBack±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
ClipClip
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/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS

D30479
Front Drive Shaft Assy RH
Snap Ring
Front Drive

Snap Ring
Transverse Engine
Engine Mounting BracketTransverse 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/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)