TOYOTA AVENSIS 2005 Service Repair Manual

D30779
LHD Steering Position Type:
RHD Steering Position Type:
D30777
D30778MP Grease 42±8
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE CLUTCH PEDAL NO.1 CUSHION
(a) LHD steering position type:
Using needle±nose pliers, remove the No.1 cushion from
the clutch pedal.
(b) RHD steering position type:
Using needle±nose pliers, remove the 2 No.1 cushions
from the clutch pedal.
13. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS BUSH
(a) Using a 8 mm hexagon wrench and a hammer, remove
the clevis bush from the clutch pedal.
14. INSTALL CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS BUSH
(a) Apply MP grease to the inside of a new clevis bush.
(b) Install the clevis bush to the clutch pedal.
HINT:
Install the clevis bush from the right side of the vehicle.

D30779
LHD Steering Position Type:
RHD Steering Position Type:
D30780MP Grease
D30781
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
42±9
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL CLUTCH PEDAL NO.1 CUSHION
(a) LHD steering position type:
Using needle±nose pliers, install the No.1 cushion to the
clutch pedal.
(b) RHD steering position type:
Using needle±nose pliers, install the 2 No.1 cushions to
the clutch pedal.
16. INSTALL CLUTCH PEDAL BUSH
(a) Apply MP grease to the inner, outer and end surface of 2
new bushes.
(b) Install the 2 bushes to the clutch pedal.
17. INSTALL CLUTCH PEDAL PAD
18. INSTALL CLUTCH PEDAL SUB±ASSY
(a) Install the clutch pedal to the clutch pedal support with the
bolt and nut.
Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)
HINT:
Install the bolt from the right side of the vehicle.

D30783MP Grease
D30775MP Grease
D26300
LHD Steering
Position Type:RHD Steering
Position Type: 42±10
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
19. INSTALL CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
(a) Apply MP grease to the inside of the turn over bush.
(b) Install the turn over bush to the clutch pedal support.
20. INSTALL CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
(a) Apply MP grease to the inside of the turn over bush.
(b) Install the turn over bush to the clutch pedal.
21. INSTALL TURN OVER SPRING SEAT COMPRESSION
SPRING (W/ TURN OVER)
(a) Apply MP grease to the contact surface of the bush and
spring.
(b) Install the spring to the clutch pedal and clutch pedal sup-
port.
22. INSTALL CLUTCH PEDAL SUPPORT SUB±ASSY
(a) LHD steering position type:
Install the clutch pedal support to the vehicle with the 2
nuts and bolt.
Torque:
Bolt: 19 N
m (195 kgf
cm, 14 ft
lbf)
Nut: 12 N
m (120 kgf
cm, 9 ft
lbf)
(b) RHD steering position type:
Install the clutch pedal support to the vehicle with the 2
bolts and 2 nuts.
Torque:
Bolt: 19 N
m (195 kgf
cm, 14 ft
lbf)
Nut: 12 N
m (120 kgf
cm, 9 ft
lbf)

D30782
LHD Steering Position Type:
RHD Steering Position Type:MP Grease
±
CLUTCH CLUTCH PEDAL SUB±ASSY (MTM)
42±11
AVENSIS REPAIR MANUAL (RM1018E)
23. 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 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.
24. INSTALL CLUTCH PEDAL SPRING
25.INSTALL COMBINATION METER ASSY (RHD STEERING POSITION TYPE) (See page 71±21)
26. INSTALL INSTRUMENT PANEL SUB±ASSY LOWER (LHD STEERING POSITION TYPE) (See page 71±11)
27.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (See page 42±2)

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)

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.

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

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.