TOYOTA AVENSIS 2003 Service Repair Manual

4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
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.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26
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4206H±01
D26321
1ZZ±FE/3ZZ±FE Engine Type:Flywheel Sub±assy Clutch Disc Assy
Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline grease x6
Clutch Release
Bearing Assy Release Bearing
Hub Clip Clutch Release
Fork Sub±assy
Clutch Cover Assy Clutch Release Fork Boot
Release Fork Support
37 (375, 27)
19 (194, 14)
±
CLUTCH CLUTCH UNIT (MTM)
42±23
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH UNIT (MTM)
COMPONENTS
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D30056Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline grease
1AZ±FSE/1AZ±FE Engine Type:
Flywheel Sub±assy
Clutch Disc Assy Clutch Release
Fork Sub±assy
Clutch Cover Assy Release Bearing
Hub Clip
Clutch Release
Bearing Assy
Release Fork Support Clutch Release
Fork Boot
48 (480, 35)
19 (194, 14)
x6
42±24
±
CLUTCH CLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
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D30057
1CD±FTV Engine Type:
Flywheel Sub±assy Clutch Disc Assy
Clutch Release Fork Sub±assy
Clutch Cover Assy
Release Bearing
Hub Clip
Clutch Release
Bearing Assy
Release Fork Support Clutch Release
Fork Boot
37 (375, 27)
19 (194, 14)
x6
Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline grease
±
CLUTCH CLUTCH UNIT (MTM)
42±25
AVENSIS REPAIR MANUAL (RM1018E)
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4200G±05
D26951
EXCEPT 1CD±FTV Engine Type:1CD±FTV Engine Type:

D25280Matchmarks
42±26
±
CLUTCH CLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
1. REMOVE MANUAL TRANSAXLE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 41±15)
(b)1AZ±FE, 1AZ±FSE Engine (See page 41±24)
(c)1CD±FTV Engine (See page 41±33) 2. REMOVE CLUTCH RELEASE FORK SUB±ASSY
(a) Remove the clutch release fork with clutch release bear-ing from the transaxle assy.
3. REMOVE CLUTCH RELEASE BEARING ASSY
(a) Remove the clutch release bearing assy from the clutch release fork.
4. REMOVE RELEASE FORK SUPPORT
(a) Remove the release fork support from the transaxle assy.
5. REMOVE RELEASE BEARING HUB CLIP
6. REMOVE CLUTCH RELEASE FORK BOOT 7. REMOVE CLUTCH COVER ASSY
(a) Align matchmarks on the clutch cover assy with the oneon the flywheel sub±assy.
(b) Loosen each set bolt one turn at a time until the spring tension is released.
(c) Remove the set bolts, and pull off the clutch cover assy.
NOTICE:
Do not drop the clutch disc assy.
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C62956
D30058
1CD±FTV Engine Type:Others:
Transaxle Side


D25281
AB
C62958
±
CLUTCH CLUTCH UNIT (MTM)
42±27
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE CLUTCH DISC ASSY
NOTICE:
Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub±assy
away from oil and foreign attachment.
9. INSPECT CLUTCH DISC ASSY
(a) Using vernier calipers, measure the rivet head depth.Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assy as necessary.
(b) Install the clutch disc assy to the transaxle assy.
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
(c) Using a dial gage, check the clutch disc assy runout. Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assy as necessary.
10. INSPECT CLUTCH COVER ASSY
(a) Using vernier calipers, inspect the diaphragm spring for
the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assy as necessary.
11. INSPECT FLYWHEEL SUB±ASSY
(a) Using a dial gage, inspect the flywheel sub±assy runout. Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub±assy as necessary.
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Q01060
D30059
1CD±FTV Engine Type:Others:
Flywheel Side
SST(s)
D26323
SST(s)
Matchmarks
7
1 (Temporally), 4
3
6
2.5 8
D00205
SST(s)
42±28
±
CLUTCH CLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
12. INSPECT CLUTCH RELEASE BEARING ASSY
(a) Turn the release bearing by hand while applying force in the axial direction.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
Replace the release bearing assy as necessary.
13. INSTALL CLUTCH DISC ASSY
(a) Insert SST(s) in the clutch disc assy, then insert them in the flywheel sub±assy.
SST 09301±00220
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
14. INSTALL CLUTCH COVER ASSY
(a) Align matchmarks on the clutch cover assy and flywheel
sub±assy.
(b) Following the procedures shown in the illustration, tighten
the 6 bolts, in the order starting from the bolt located near
the knock pin on the top.
Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
HINT:

Following the order in the illustration, tighten the bolts at
a time evenly.

Move SST(s) up and down, right and left lightly, after
checking that the disc is in the center, and then tighten the
bolts.
15. INSPECT AND ADJUST CLUTCH COVER ASSY
(a) Using a dial indicator with roller instrument, check the dia- phragm spring tip alignment.
Maximum non±alignment: 0.5 mm (0.020 in.)
If the alignment is not as specified, adjust the diaphragm spring
tip alignment using SST(s). SST 09333±00013
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D26819
EXCEPT 1CD±FTV Engine Type:
1CD±FTV Engine Type:
Release Hub Grease
±
CLUTCH CLUTCH UNIT (MTM)
42±29
AVENSIS REPAIR MANUAL (RM1018E)
16. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the transaxle assy.
Torque:
1ZZ±FE/3ZZ±FE/1CD±FTV Engine Type: 37 N
m (375 kgf
cm, 27 ft
lbf)
1AZ±FSE/1AZ±FE Engine Type: 47 N
m (480 kgf
cm, 35 ft
lbf)
17. INSTALL RELEASE BEARING HUB CLIP
18. INSTALL CLUTCH RELEASE FORK SUB±ASSY
(a) Apply the release hub grease to the release fork and re-lease bearing assy contact, release fork and push rod
contact, and release fork pivot points.
Sealant:
Part No. 08887±01806, RELEASE HUB GREASE or
equivalent
(b) Install the release fork to the release bearing assy.
19. INSTALL CLUTCH RELEASE BEARING ASSY
(a) Apply the clutch spline grease to the input shaft spline. Sealant:
Part No. 08887±01706, CLUTCH SPLINE GREASE or equivalent
(b) Install the bearing to the release fork, and then install them to the tr\
ansaxle assy.
NOTICE:
After the installation, move the folk forward and backward to check that\
the release bearing slides
smoothly.
20. INSTALL CLUTCH RELEASE FORK BOOT
21. INSTALL MANUAL TRANSAXLE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 41±15)
(b)1AZ±FE, 1AZ±FSE Engine (See page 41±24)
(c)1CD±FTV Engine (See page 41±33)
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5006Z±01
50±20
±
STEERING COLUMN POWER STEERING ECU ASSY
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING ECU ASSY
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.1 (See page 71±11)
4.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
5.REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 71±11)
6.REMOVE STEERING COLUMN COVER LWR (See page 50±9)
7. REMOVE STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY (See page 50±9)
8.REMOVE COMBINATION METER ASSY (See page 71±11)
9.REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (See page 71±11)
10.REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2(See page 71±11)
11.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
12.REMOVE FRONT PILLAR GARNISH LH (See page 71±11)
13.REMOVE FRONT PILLAR GARNISH RH (See page 71±11)
14.DISCONNECT PASSENGER AIRBAG CONNECTOR(See page 71±11)
15. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG
ASSY (See page 71±11)
16. REMOVE POWER STEERING ECU ASSY
NOTICE:
Thoroughly check the procedures for removing and instal-
ling the power steering ECU assy when replacing it. Do the
same for the removing and installing the steering column
assy.
(a) Mark the clamp position on the torque sensor wire har-ness in order to reinstall the wire harness as shown in the
illustration.
(b) Disconnect the torque sensor wire harness from the clamp.
NOTICE:
In case the clamp will be reused, pay attention so as not to
damage it.
(c) Disconnect the 4 connectors.
(d) LHD: (1) Remove the 2 bolts,screw and power steering ECUassy.
(e) RHD: (1) Remove the 2 bolts,2 screw and power steeringECU assy.
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F44857F44857
LHD:RHD:
Torque Sensor Wire Harness Clamp
Marks
Power Steering ECU Assy
Front
Motor Wire Harness
Torque Sensor
Wire Harness
Front
Torque Sensor
Wire Harness
Motor Wire Harness
Power Steering ECU Assy
Torque Sensor Wire Harness Clamp
Marks
Bolt (A)
Bolt (B)
Screw Screw
Bolt (B) Bolt (A)
±
STEERING COLUMN POWER STEERING ECU ASSY
50±21
AVENSIS REPAIR MANUAL (RM1018E)
17. INSTALL POWER STEERING ECU ASSY
(a) LHD:
Install the power steering ECU assy with the 2 bolts and
screw.
Torque:
BOLT (A): 8.0 N
m (82 kgf
cm, 71 in.
lbf)
BOLT (B): 15.5 N
m (158 kgf
cm, 11 ft
lbf)
(b) RHD:
Install the power steering ECU assy with the 2 bolts and
2 screws.
Torque:
BOLT (A): 8.0 N
m (82 kgf
cm, 71 in.
lbf)
BOLT (B): 15.5 N
m (158 kgf
cm, 11 ft
lbf)
(c) Connect the 4 connectors.
(d) Align the marks on the torque sensor wire harness with the clamp, as shown in the illustration.
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