TOYOTA AVENSIS 2002 Repair Manual

4100Z±05
D25304
0 to 5 mm
(0 to 0.20 in.) 41±2
± MANUAL TRANSMISSION/TRANSAXLEMANUAL 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)

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)

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.

D30071
D26893
D26895
D30071
D26972
41±8
± MANUAL TRANSMISSION/TRANSAXLETRANSMISSION 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.

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)

3306E±05
Parking Brake
Shoe Hold±Down
Compression Spring
Parking Brake Shoe
Adjusting Screw SetParking Brake
Shoe Strut LH
F44821
Parking Brake
Shoe Lever LH
Parking Brake
Shoe Assy LH No.2
Parking Brake
Shoe Assy LH No.1
Parking Brake Shoe
Hold±Down Spring Pin
Parking Brake Shoe
Hold±Down Spring Pin
Parking Brake Shoe
Hold±Down Compression Spring
Tension Spring
Tension Spring
Tension Spring
Rear Disc
Rear Disc Brake
Caliper Assy LH
47(475, 34)
N
m (kgf
cm, ft
lbf) : Specified torque
High temperature grease
± PARKING BRAKEPARKING BRAKE ASSY
33±13
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE ASSY
COMPONENTS

330C8±01
F45710
Contract
F06409
G22379

G22380
33±14
±
PARKING BRAKE PARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures as those of the LH side.
1. REMOVE REAR WHEEL
2.DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (See page 30±31) 3. REMOVE REAR DISC
(a) Release the parking brake, and remove the rear disc.
HINT:

Put matchmarks on the disc and the axle hub.

If the disc cannot be removed easily, turn the shoe adjust-
er until the wheel turns freely.
4. INSPECT BRAKE DISC INSIDE DIAMETER
(a) Using a brake drum gauge or equivalent, measure the in- side diameter of the disc.
Standard inside diameter: 173 mm (6.81 in.)
Maximum inside diameter: 174 mm (6.85 in.)
5. REMOVE PARKING BRAKE ADJUSTER KIT
(a) Using needle±nose pliers, remove the shoe upper side 2 tension springs.
(b) Remove the parking brake shoe strut LH.
6. REMOVE PARKING BRAKE SHOE ADJUSTING
SCREW SET
(a) Using needle±nose pliers, remove the anchor side ten- sion spring.
(b) Remove the shoe adjusting screw set.


F45077
SST
F44822
SST
R00311
BR0828
F42661
± PARKING BRAKEPARKING BRAKE ASSY
33±15
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE PARKING BRAKE SHOE KIT
(a) Using SST, remove the parking brake shoe hold±down
compression spring, parking brake shoe hold±down
spring pin and parking brake shoe assy LH No.1.
SST 09718±00010
(b) Using SST, remove the parking brake shoe hold±down
compression spring and parking brake shoe hold±down
spring pin.
SST 09718±00010
(c) Disconnect the parking brake shoe assy LH No.2 from the
parking brake shoe lever LH, and remove the parking
brake shoe LH No.2.
8. INSPECT PARKING BRAKE SHOE LINING
THICKNESS
(a) Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 3.5 mm (0.138 in.)
Minimum thickness: 1.0 mm (0.039 in.)
9. INSPECT BRAKE DISC AND PARKING BRAKE SHOE
LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the disc, then grind
down the brake shoe lining to fit.
If the contact between the brake disc and the shoe lining is im-
proper, repair it using a brake shoe grinder or replace the brake
shoe assembly.
10. REMOVE PARKING BRAKE SHOE LEVER LH
(a) Using needle±nose pliers, disconnect the parking brake
cable assy No.3 and remove the parking brake shoe lever
LH.


F44709
F42661
C80704
F44822
SST
F44705
SST
33±16
± PARKING BRAKEPARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
11. APPLY HIGH TEMPERATURE GREASE
(a) Apply the high temperature grease to the shoe attached
surface of backing plate.
12. INSTALL PARKING BRAKE SHOE LEVER LH
(a) Using needle±nose pliers, connect the parking brake
cable assy No.3 to the parking brake shoe lever LH.
13. INSTALL PARKING BRAKE SHOE KIT
(a) Apply the high temperature grease to the contact part of
the parking brake shoe and parking brake shoe lever.
(b) Using SST, install the parking brake shoe LH No.2 with
the parking brake shoe hold±down compression spring
and parking brake shoe hold±down spring pin.
SST 09718±00010
(c) Using SST, install the parking brake shoe LH No.1 with
the parking brake shoe hold±down compression spring
and parking brake shoe hold±down spring pin.
SST 09718±00010

C80705

G22380
C80706
G22379
± PARKING BRAKEPARKING BRAKE ASSY
33±17
AVENSIS REPAIR MANUAL (RM1018E)
14. INSTALL PARKING BRAKE SHOE ADJUSTING
SCREW SET
(a) Apply the high temperature grease to the adjusting bolt
and support piece.
(b) Install the parking brake shoe adjusting screw set LH.
(c) Using needle±nose pliers, install the tension spring.
15. INSTALL PARKING BRAKE ADJUSTER KIT
(a) Apply the high temperature grease to the contact part of
the shoe strut and tension spring.
(b) Install the parking brake shoe strut LH.
(c) Using needle±nose pliers, install the upper side 2 tension
springs.
HINT:
Install the 2 tension spring securely to the grooves of the shoe
strut.