boot TOYOTA AVENSIS 2005 Service Owner's Manual

F45420
Front Disc Brake Cylinder Mounting
Bush Dust Boot
F45418
C64095
G23222
G23223
32±42
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Remove the 2 front disc brake bush dust boots from the
front disc brake cylinder mounting LH.
7. REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and front disc brake cylinder mount-
ing LH.
8. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rug between the front disc brake piston and
the disc brake cylinder assy LH.
(b) Use compressed air to remove the front disc brake piston
from the disc brake cylinder assy LH.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
NOTICE:
Do not spatter the brake fluid.
9. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the cylinder boot.
10. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal.
NOTICE:
Do not damage the inner cylinder and cylinder groove.

G23226Lithium soap base glycol grease
Cylinder Boot
Piston
G23225
Cylinder Boot
Piston
F45418
F45420
Front Disc Brake Cylinder Mounting
Bush Dust Boot
Lithium soap base glycol grease
32±44
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
18. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the disc brake cylinder assy LH.
(b) Install the bleeder plug cap to the bleeder plug.
19. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assy LH.
20. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front disc
brake piston and a new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the piston to the disc brake cylinder assy LH.
NOTICE:
Do not install the piston forcibly in the disc brake cylinder.
21. INSTALL CYLINDER BOOT
(a) Using SST and a hammer, install the cylinder boot to the
disc brake cylinder assy LH.
SST 09550±60010
NOTICE:
Do not damage the cylinder boot.
HINT:
Install the boot securely to the disc brake cylinder assy LH.
22. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
LH
(a) Install the front disc brake cylinder mounting LH with the
2 bolts.
Torque: 102 N
m (1,040 kgf
cm, 75 ft
lbf)
23. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to the sealing sur-
face of 2 new front disc brake bush dust boots.
(b) Install the 2 front disc brake bush dust boots to the front
disc brake cylinder mounting LH.

320GA±03
G23177
Disc Brake
Cylinder Assy LH
GasketFlexible Hose
Disc Brake
Pad Kit Front
Front Disc Brake
Pad Support Plate No.1
Front Disc Brake
Cylinder Slide Pin (No.2)
Front Disc Brake
Bush Dust Boot Front Disc Brake
Cylinder Slide Pin (No.1)
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Cylinder Mounting LH

Cylinder Boot
Piston Seal
Front Disc
Brake PistonFront Disc
30 (306, 22)
102 (1,040, 75)
30 (306, 22)
Bleeder Plug CapFront Disc Brake
Bleeder Plug

Non±reusable part
N
m (kgf
cm, ft
lbf) : Specified torque
Lithium soap base glycol grease
29 (296, 21)
10 (102, 7)
Union bolt
Front Disc Brake
Pad Support Plate No.2
102 (1,040, 75)

Front Disc Brake
Bush Dust Boot
Bolt

Bolt




32±40
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BRAKE
COMPONENTS

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.

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)

4206H±01
D26321
1ZZ±FE/3ZZ±FE Engine Type:
Flywheel Sub±assyClutch Disc Assy
Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline greasex6
Clutch Release
Bearing Assy
Release Bearing
Hub ClipClutch Release
Fork Sub±assy
Clutch Cover Assy
Clutch Release Fork Boot Release Fork Support
37 (375, 27)
19 (194, 14)
± CLUTCHCLUTCH UNIT (MTM)
42±23
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH UNIT (MTM)
COMPONENTS

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 AssyRelease Bearing
Hub Clip Clutch Release
Bearing Assy
Release Fork Support
Clutch Release
Fork Boot
48 (480, 35)
19 (194, 14)
x6 42±24
± CLUTCHCLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)

D30057
1CD±FTV Engine Type:
Flywheel Sub±assyClutch 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
± CLUTCHCLUTCH UNIT (MTM)
42±25
AVENSIS REPAIR MANUAL (RM1018E)

D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:
D26804
42±18
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE CLUTCH RELEASE CYLINDER ASSY
(EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type:
Remove the 3 bolts, clutch release cylinder assy, and
clutch line bracket.
(b) 1AZ±FE/1AZ±FSE Engine Type:
Remove the 3 bolts and clutch release cylinder assy.
6. REMOVE CLUTCH RELEASE CYLINDER ASSY
(1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, remove the 2 bolts
and clutch release cylinder assy.
7. REMOVE CLUTCH RELEASE CYLINDER KIT
(a) Remove the boot from the cylinder body.
(b) Remove the push rod from the cylinder body.
(c) Remove the piston from the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(d) Remove the spring from the cylinder body.
(e) Remove the bleeder plug cap from the bleeder plug.
8. REMOVE RELEASE CYLINDER BLEEDER PLUG
9. INSTALL RELEASE CYLINDER BLEEDER PLUG
Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)

CL0672
D26804
D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:(1)
(1)
(1)
(1)
(2) (2)
± CLUTCHCLUTCH RELEASE CYLINDER ASSY (MTM)
42±19
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL CLUTCH RELEASE CYLINDER KIT
(a) Install the bleeder plug cap to the bleeder plug.
(b) Install a new spring to the cylinder body.
(c) Coat the parts with lithium soap base glycol grease, as
shown in the illustration.
(d) Install the piston to the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(e) Install the push rod to the cylinder body.
(f) Install the boot to the cylinder body.
11. INSTALL CLUTCH RELEASE CYLINDER ASSY
(1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, install the clutch re-
lease cylinder assy with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
12. INSTALL CLUTCH RELEASE CYLINDER ASSY
(EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type:
(1) Install the clutch release cylinder and clutch line
bracket with the 2 bolts.
Torque: 14 N
m (141 kgf
cm, 10 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(b) 1AZ±FE/1AZ±FSE Engine Type:
(1) Install the clutch release cylinder with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)