4105U–03
D30489
Gasoline Engine:Front FloorHeat Insulator No.1
Console Box Carpet
Floor Shift Lever KnobSub–assy
Console Panel Sub–assy Upper
Console Panel Sub–assy Lower
Console Box Sub–assy Rear
Clip
Clip
Clip
5.0 (51, 44 in. �lbf)
5.0 (51, 44 in. �lbf)
Clip Clip
12 (122, 9)
Floor Shift Shift Lever Assy
12 (122, 9)
N·m (kgf·cm, ft·lbf) : Specified torque
5.5 (56, 49 in. �lbf)
Transmission Control Cable Assy
41–10–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
FLOOR SHIFT SHIFT LEVER ASSY (MTM)COMPONENTS
410DR–01
D26893
D26895
D30474
D30474
–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)41–11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT1. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB–ASSY (See page 71–11)2. REMOVE CONSOLE PANEL UPPER (See page 71–11)3. REMOVE CONSOLE PANEL SUB–ASSY LOWER (See page 71–11)4. REMOVE CONSOLE BOX ASSY REAR (See page 71–11)
5. SEPARATE TRANSMISSION CONTROL CABLE ASSY(a) Remove the 2 clips, separate the cable ends of the control
cable assy.
(b) Release the claws, separate the control cable assy.
6. REMOVE FLOOR SHIFT SHIFT LEVER ASSY(a) Remove the 4 bolts and shift lever assy.
7. INSTALL FLOOR SHIFT SHIFT LEVER ASSY(a) Install the shift lever assy with the 4 bolts.
Torque: 12 N �m (122 kgf �cm, 9 ft �lbf)
D26972
D26894
Serrate Part
41–12–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
8. CONNECT TRANSMISSION CONTROL CABLE ASSY(a) Connect the control cable assy to the shift lever assy.NOTICE:Make sure that the claws are firmly engaged.
(b) Connect the end of the select cable to the shift lever assy,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.(c) Connect the end of the shift cable to the shift lever assy.
41046–11
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)41–3
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (C50/C250)REPLACEMENT1. DRAIN MANUAL TRANSAXLE OIL
Torque: 39 N �m (400 kgf �cm, 29 ft �lbf)2. REMOVE FRONT WHEELS3. REMOVE ENGINE UNDER COVER LH4. REMOVE ENGINE UNDER COVER RH5. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)
SST 09520–01010, 09520–24010 (09520–32040)6. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6)
SST 09520–01010, 09520–24010 (09520–32040)
7. REMOVE TRANSAXLE CASE OIL SEAL(a) Using SST(s), remove the oil seal.
SST 09308–00010
8. REMOVE TRANSMISSION CASE OIL SEAL(a) Using SST(s), remove the oil seal.
SST 09308–00010
9. INSTALL TRANSAXLE CASE OIL SEAL(a) Coat a new oil seal lip with MP grease.(b) Using SST(s) and a hammer, install the oil seal.
SST 09554–14010, 09950–70010 (09951–07200)Drive in depth: 1.9 � 0.3 mm (0.075 � 0.012 in.)
NOTICE:Be careful not to damage the oil seal lip.
D26133
SST(s)
D25304
0 to 5 mm (0 to 0.20 in.)
41–4–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL(a) Coat a new oil seal lip with MP grease.(b) Using SST(s) and a hammer, install the oil seal.
SST 09554–14010, 09950–70010 (09951–07200)Drive in depth: 9.9 � 0.3 mm (0.390 � 0.012 in.)
NOTICE:Be careful not to damage the oil seal lip.
11. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–6)12. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–6)13. INSTALL FRONT WHEELS
Torque: 103 N �m (1,050 kgf �cm, 76 ft �lbf)
14. ADD MANUAL TRANSAXLE OILOil grade: API GL–4 or GL–5Viscosity: SAE 75 W–90Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)Torque: 39 N �m (400 kgf �cm, 29 ft �lbf)
15. INSPECT MANUAL TRANSAXLE OIL (See page 41–2)16. INSPECT FRONT WHEEL ALIGNMENT (See page 26–6)17. CHECK ABS SPEED SENSOR SIGNAL(a) w/ VSC (See page 05–756)(b) w/o VSC (See page 05–699)
41046–12
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)41–5
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (E354/E357)REPLACEMENT1. DRAIN MANUAL TRANSAXLE OIL
Torque: 49 N �m (500 kgf �cm, 36 ft �lbf)2. REMOVE FRONT WHEELS3. REMOVE ENGINE UNDER COVER LH4. REMOVE ENGINE UNDER COVER RH5. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)
SST 09520–01010, 09520–24010 (09520–32040)6. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6)
SST 09520–01010, 09520–24010 (09520–32040)
7. REMOVE FRONT TRANSAXLE CASE COVER OILSEAL
(a) Using SST(s), remove the oil seal.SST 09308–00010
8. REMOVE TRANSMISSION CASE OIL SEAL(a) Using SST(s), remove the oil seal.
SST 09308–00010
9. INSTALL FRONT TRANSAXLE CASE COVER OILSEAL
(a) Coat a new oil seal lip with MP grease.(b) Using SST(s) and a hammer, install the oil seal.
SST 09608–10010, 09950–70010 (09951–07200)Drive in depth: 0 � 0.5 mm (0 � 0.020 in.)
NOTICE:Be careful not to damage the oil seal lip.
D26133
SST(s)
D25304
0 to 5 mm (0 to 0.20 in.)
41–6–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL(a) Coat a new oil seal lip with MP grease.(b) Using SST(s) and a hammer, install the oil seal.
SST 09608–32010, 09950–70010 (09951–07200)Drive in depth: 3.5 � 0.5 mm (0.138 � 0.020 in.)
NOTICE:Be careful not to damage the oil seal lip.
11. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–6)12. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–6)13. INSTALL FRONT WHEELS
Torque: 103 N �m (1,050 kgf �cm, 76 ft �lbf)
14. ADD MANUAL TRANSAXLE OILOil grade: API GL–4 or GL–5Viscosity: SAE 75 W–90Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts)Torque: 49 N �m (500 kgf �cm, 36 ft �lbf)
15. INSPECT MANUAL TRANSAXLE OIL (See page 41–2)16. INSPECT FRONT WHEEL ALIGNMENT (See page 26–6)17. CHECK ABS SPEED SENSOR SIGNAL(a) w/ VSC (See page 05–756)(b) w/o VSC (See page 05–699)
410DT–01
D30082
13 (133, 10)Hood Sub–assy
Engine Cover Sub–assy No.1
Air Cleaner Assy
Battery
Battery Tray
Clip
Clip
Clip
Starter Assy
64 (653, 47)
80 (816, 59)
52 (530, 38)18 (184, 13)
� Non–reusable partN·m (kgf·cm, ft·lbf) : Specified torque
12 (120, 9)
Manual Transaxle Assy
46 (469, 34)
Transverse Engine Engine Mounting Insulator
9.0 (92, 80 in. �lbf)
Engine Room Cover Side
Radiator Support Opening Cover
44 (449, 32)
44 (449, 32)
Clutch Release Cylinder Assy
Starter Connector
37 (380, 27)
13 (130, 9)
46 (469, 34)
8.4 (85, 74 in. �lbf)
46 (469, 34)
Transmission Control Cable Assy
Battery Clamp Sub–assy
5.0 (51, 44 in. �lbf)
9.0 (92, 80 in. �lbf)
Back–up Lamp Switch Connector
5.0 (51, 44 in. �lbf)
Clip
26 (260, 19)
40 (410, 30)
64 (653, 47)
52 (530, 38)
13 (131, 9)
41–22–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)COMPONENTS
D30473
Front Drive Shaft Assy RH
� Snap Ring
Transverse EngineEngine Mounting Insulator
64 (653, 47)
87 (887, 64)
� Cotter Pin64 (653, 47)
� 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)
49 (500, 36)
89 (908, 66)
Transverse EngineEngine Mounting Bracket
133 (1,356, 83)
52 (530, 38) 89 (908, 66)
29 (296, 21)Transverse EngineEngine Mounting Insulator
Transverse EngineEngine Mounting Bracket
8.0 (82, 71 in. �lbf)
74 (755, 55)
Front Drive Shaft Assy LH
64 (650, 47)
64 (650, 47)
–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)41–23
AVENSIS REPAIR MANUAL (RM1018E)
410DU–01
D30480
D30081
41–24–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT1. INSPECT CENTER FRONT WHEEL2. 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 WHEELS7. REMOVE ENGINE UNDER COVER LH8. REMOVE ENGINE UNDER COVER RH9. DRAIN TRANSAXLE OIL
Torque: 49 N �m (500 kgf �cm, 36 ft �lbf)10. REMOVE HOOD SUB–ASSY11. REMOVE RADIATOR SUPPORT OPENING COVER12. REMOVE ENGINE ROOM COVER SIDE13. REMOVE ENGINE COVER SUB–ASSY NO.114. REMOVE AIR CLEANER ASSY15. REMOVE BATTERY CLAMP SUB–ASSY16. REMOVE BATTERY17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER(a) Remove the 4 bolts and battery carrier.
19. REMOVE STARTER ASSY (See page 19–12)
20. SEPARATE WIRE HARNESS(a) Remove the 3 bolts, and separate the 3 wire harnesses.
D30066
D30064
G24413
–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)41–25
AVENSIS REPAIR MANUAL (RM1018E)
21. SEPARATE CONNECTOR(a) Separate the back–up lamp switch connector.
22. SEPARATE CLUTCH RELEASE CYLINDER ASSY(a) Remove the 3 bolts and separate the release cylinder.
23. 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.
24. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)SST 09520–01010, 09520–24010 (09520–32040)
25. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6)26. REMOVE HEIGHT CONTROL SENSOR SUB–ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65–28)27. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51–36)
SST 09023–1270028. DISCONNECT PRESSURE FEED TUBE ASSY (See page 51–36)
SST 09023–12700
D25745
No.1 Engine Hanger No.2 Engine Hanger
D30067
D30077
D25747
41–26–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)
AVENSIS REPAIR MANUAL (RM1018E)
29. SUSPEND ENGINE ASSY(a) Install the No.1 and No.2 engine hangers in the correct
direction.Parts No.:No. 1 engine hanger: 12281–28010No. 2 engine hanger: 12282–28010Bolt: 91512–61020Torque: 38 N �m (387 kgf �cm, 28 ft �lbf)
(b) Attach the engine chain hoist to the engine hanger.CAUTION:Do not attempt to hang the engine by hooking the chain toany other part.
30. REMOVE FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–26)31. SUPPORT MANUAL TRANSAXLE ASSY(a) Support the manual transaxle with a transmission jack.
32. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulatorLH.
33. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket.
34. REMOVE MANUAL TRANSAXLE ASSY(a) Separate the wire harness clamp.(b) Remove the 10 bolts.(c) Separate and remove the transaxle from the engine.
D30076
D30078
D30079
D30079
(a)
(a)
(a)(b)
D30078
(a)
(b)
(b)
(a)
–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)41–27
AVENSIS REPAIR MANUAL (RM1018E)
35. REMOVE MANUAL TRANSMISSION CASEPROTECTOR
(a) Remove the 2 bolts and case protector.
36. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FRfrom the engine mounting bracket.
(b) Remove the 2 bolts and engine mounting bracket FR fromthe transaxle.
37. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR fromthe engine mounting bracket.
(b) Remove the 3 bolts and engine mounting bracket RRfrom the transaxle.
38. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGBRACKET
(a) Install the engine mounting bracket RR and 3 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)
(b) Install the engine mounting insulator RR and bolt to theengine mounting bracket RR.Torque: 87 N �m (887 kgf �cm, 64 ft �lbf)
39. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGBRACKET
(a) Install the engine mounting bracket FR and 2 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)
(b) Install the engine mounting insulator FR, bolt and nut tothe engine mounting bracket FR.Torque: 52 N �m (530 kgf �cm, 38 ft �lbf)
D30076
D25747
AB
CB
A
D30077
D30067
A
A
A
A
B
41–28–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)
AVENSIS REPAIR MANUAL (RM1018E)
40. INSTALL MANUAL TRANSMISSION CASEPROTECTOR
(a) Install the case protector with the 2 bolts.Torque: 18 N �m (184 kgf �cm, 13 ft �lbf)
41. INSTALL MANUAL TRANSAXLE ASSY(a) Align the input shaft with the clutch disc and install the
transaxle to the engine.(b) Install the 10 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: 44 N �m (449 kgf �cm, 32 ft �lbf)
(c) Connect the wire harness clamp.
42. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGBRACKET
(a) Install the engine mounting bracket LH to the transaxlewith the 3 bolt.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)
43. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGINSULATOR
(a) Install the engine mounting insulator LH with the 5 boltsand nut.Torque:Bolt A: 52 N �m (530 kgf �cm, 38 ft �lbf)Bolt B: 80 N �m (816 kgf �cm, 59 ft �lbf)
44. INSTALL FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–26)SST 09670–00010
45. CONNECT PRESSURE FEED TUBE ASSY (See page 51–36)SST 09023–12700
46. CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51–36)SST 09023–12700
47. INSTALL HEIGHT CONTROL SENSOR SUB–ASSY FR RH (W/ DISCHARGE HEAD LAMP)(See page 65–28)
48. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–6)49. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–6)
G24413
D30064
A
B
D30066
D30081
B
C
A
–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)41–29
AVENSIS REPAIR MANUAL (RM1018E)
50. INSTALL TRANSMISSION CONTROL CABLE ASSY(a) Connect the 2 cable ends, install the 2 clips.(b) Install the 2 clips to the control cable bracket.
51. INSTALL CLUTCH RELEASE CYLINDER ASSY(a) Install the release cylinder with the 3 bolts.
Torque:Bolt A: 9.0 N �m (92 kgf �cm, 80 in. �lbf)Bolt B: 12 N �m (120 kgf �cm, 9 ft �lbf)
52. CONNECT CONNECTOR(a) Connect the back–up lamp switch connector.
53. CONNECT WIRE HARNESS(a) Install the 3 wire harnesses with the 3 bolts.
Torque: Bolt A: 26 N �m (260 kgf �cm, 19 ft �lbf)Bolt B: 8.4 N �m (85 kgf �cm, 74 in. �lbf)Bolt C: 40 N �m (410 kgf �cm, 30 ft �lbf)
54. INSTALL STARTER ASSY (See page 19–12)
D30080
41–30–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER(a) Install the battery carrier and 4 bolts.
Torque: 13 N �m (131 kgf �cm, 9 ft �lbf)
56. INSTALL BATTERY TRAY57. INSTALL BATTERY58. 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)
59. INSTALL AIR CLEANER ASSYTorque: 5.0 N �m (51 kgf �cm, 44 in. �lbf)
60. INSTALL ENGINE COVER SUB–ASSY NO.1Torque: 9.0 N �m (92 kgf �cm, 80 in. �lbf)
61. INSTALL ENGINE ROOM COVER SIDE62. INSTALL RADIATOR SUPPORT OPENING COVER63. INSTALL HOOD SUB–ASSY
Torque: 13 N �m (132 kgf �cm, 10 ft �lbf)64. INSPECT HOOD SUB–ASSY (See page 75–2)65. ADJUST HOOD SUB–ASSY (See page 75–2)66. ADD TRANSAXLE OIL (See page 41–5)67. INSPECT TRANSAXLE OIL (See page 41–2)68. INSTALL FRONT WHEELS
Torque: 103 N �m (1,050 kgf �cm, 76 ft �lbf)69. INSTALL STEERING INTERMEDIATE SHAFT (See page 50–9)70. INSTALL STEERING COLUMN HOLE COVER SUB–ASSY NO.1 (See page)See page 50–9)71. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50–9)72. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50–9)73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD74. STEERING WHEEL CENTER POINT75. ADD POWER STEERING FLUID76. BLEED POWER STEERING FLUID (See page 51–4)77. CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51–4)78. INSPECT FLUID LEAK (See page 51–4)79. INSPECT FRONT WHEEL ALIGNMENT (See page 26–6)80. INSTALL ENGINE UNDER COVER LH81. INSTALL ENGINE UNDER COVER RH82. CHECK ABS SPEED SENSOR SIGNAL(a) w/ VSC (See page 05–756)(b) w/o VSC (See page 05–699)83. HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65–19)
410DV–01
D30475
13 (133, 10)Hood Sub–assy
Radiator Reserve Tank Assy
Engine Cover No.1
5.0 (51, 44 in. �lbf)
7.0 (71, 62 in. �lbf)
Air Cleaner Assy
Battery ClampSub–assy
3.5 (36, 31 in. �lbf)
Battery
Battery Tray
Clip
Clip
Clip
Floor Shift TransmissionControl Cable Assy
Starter Assy
Starter Connector
Ground Cable
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)
Manual TransmissionCase Protector
64 (653, 47)
40 (408, 30)
20 (200, 14)
8.0 (82, 71 in. �lbf)
40 (408, 30)
64 (653, 47)
� Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torque
12 (120, 9)
5.0 (51, 44 in. �lbf)
64 (653, 47)
Manual Transaxle Assy
13 (133, 10)
37 (380, 27)
46 (469, 34)
13 (130, 9)
Transverse Engine Engine Mounting Insulator
9.0 (92, 80 in. �lbf)
8.0 (82, 71 in. �lbf)
6.0 (61, 53 in. �lbf)
52 (530, 38)
25 (255, 18)
Air Tube No.1
25 (255, 18)
Engine Room Cover Side
Radiator Support Opening Cover
Clip
13 (131, 9)
12 (120, 9)
–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD–FTV)41–31
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1CD–FTV)COMPONENTS
D30476
Front Drive Shaft Assy RH
Front Drive Shaft Assy LH
� Snap Ring
Transverse EngineEngine Mounting Bracket
Transverse EngineEngine Mounting
Transverse EngineEngine Mounting Bracket
64 (653, 47)
� Cotter Pin
52 (530, 38)
� Cotter Pin
49 (500, 36) 8.0 (82, 71 in. �lbf)
� 216 (2,203, 159)
� Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torque
Engine Under Cover RHEngine Under Cover LH
Transverse EngineEngine Mounting Bracket
64 (650, 47)
64 (650, 47)
64 (653, 47)
87 (887, 64)
64 (653, 47)
49 (500, 36)
133 (1,356, 83)
45 (459, 33)
29 (296, 21)
52 (530, 38)
74 (755, 55)
74 (755, 55)
89 (908, 66)
133 (1,356, 83)
52 (530, 38)
89 (908, 66)
35.3 (360, 26)
41–32–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD–FTV)
AVENSIS REPAIR MANUAL (RM1018E)
410DY–01
D26902
D26903
–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD–FTV)41–33
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT1. INSPECT CENTER FRONT WHEEL2. 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 WHEELS7. REMOVE ENGINE UNDER COVER RH8. REMOVE ENGINE UNDER COVER LH9. DRAIN TRANSAXLE OIL
Torque: 49 N �m (500 kgf �cm, 36 ft �lbf)10. REMOVE HOOD SUB–ASSY11. REMOVE RADIATOR SUPPORT OPENING COVER12. REMOVE ENGINE ROOM COVER SIDE13. REMOVE ENGINE COVER NO.114. REMOVE AIR CLEANER ASSY15. REMOVE BATTERY CLAMP SUB–ASSY16. REMOVE BATTERY17. REMOVE BATTERY TRAY18. REMOVE AIR TUBE NO.1 (See page 14–286)
19. SEPARATE RADIATOR RESERVE TANK ASSY(a) Remove the 2 bolts, separate the radiator reserve tank
assy.
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 withbrackets 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) 12284–27020No.1 engine hanger UPR (black) 12284–27030No.1 engine hanger 12281–27050No.2 engine hanger (yellow) 12282–27060No.2 engine hanger (black) 12282–27070Bolt: 91642–81025Torque: 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 toany 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 insulatorLH from the body.
36. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH fromthe transaxle.
D26918
D30076
D30074
D30075
D30075
(b)
(a)
(a)
(a)
41–36–MANUAL TRANSMISSION/TRANSAXLE MANUAL 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 CASEPROTECTOR
(a) Remove the 2 bolts and case protector.
39. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FRfrom the engine mounting bracket.
(b) Remove the 2 bolts and engine mounting bracket FR fromthe transaxle.
40. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR fromthe engine mounting bracket.
(b) Remove the 3 bolts and engine mounting bracket RRfrom the transaxle.
41. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGBRACKET
(a) Install the engine mounting bracket RR and 3 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)
(b) Install the engine mounting insulator RR and bolt to theengine mounting bracket.Torque: 87 N �m (887 kgf �cm, 64 ft �lbf)
D30074
(a)
(b)
(a)
(b)
D30076
D26918
A
BC
D
E
D30073
D30072
A
A
A
A
B
A
–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD–FTV)41–37
AVENSIS REPAIR MANUAL (RM1018E)
42. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGBRACKET
(a) Install the engine mounting bracket FR and 2 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)
(b) Install the engine mounting insulator FR, bolt and nut tothe engine mounting bracket.Torque: 52 N �m (530 kgf �cm, 38 ft �lbf)
43. INSTALL MANUAL TRANSMISSION CASEPROTECTOR
(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 MOUNTINGBRACKET
(a) Install the engine mounting bracket LH to the transaxlewith the 3 bolts.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)
46. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGINSULATOR
(a) Install the engine mounting insulator LH with the 5 boltsand 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
A
B
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 TRAY63. INSTALL BATTERY64. 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 ASSYTorque: 7.0 N �m (71 kgf �cm, 62 in. �lbf)
66. INSTALL ENGINE COVER NO.1Torque: 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 AHEAD72. STEERING WHEEL CENTER POINT73. INSTALL ENGINE ROOM COVER SIDE74. INSTALL RADIATOR SUPPORT OPENING COVER
41–40–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD–FTV)
AVENSIS REPAIR MANUAL (RM1018E)
75. INSTALL HOOD SUB–ASSYTorque: 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 FLUID81. 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 RH87. INSTALL ENGINE UNDER COVER LH88. 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 AssyBattery Carrier
Transmission Control Cable Assy
Clip
Air Cleaner Assy
Hood Sub–assy
Cylinder Head Cover No.2
Starter Assy
Back–up Lamp SwitchConnector
Transverse EngineEngine Mounting Bracket
Clip
Clip
Clip
Clip
37 (380, 27)
Starter Connector
Transverse EngineEngine 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/TRANSAXLE MANUAL 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 RingFront Drive
� Snap Ring
Transverse EngineEngine Mounting Bracket
Transverse EngineEngine Mounting Insulator
64 (653, 47)
87 (887, 64)Transverse EngineEngine 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/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ–FE/3ZZ–FE)
AVENSIS REPAIR MANUAL (RM1018E)
4100Z–05
D25304
0 to 5 mm(0 to 0.20 in.)
41–2–MANUAL TRANSMISSION/TRANSAXLE MANUAL 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 TABLEUse the table below to help find the cause of the problem. The numbers indicate the likelihood of the possiblecause 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 TRANSAXLE RepairManual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E)
Symptom Suspect Area See 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)REPLACEMENTHINT:COMPONENTS: See page 41–101. REMOVE AIR CONDITIONER UNIT ASSY (See page 55–55)HINT:Refer to the instructions for removal of the instrument panel sub–assy 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/TRANSAXLE TRANSMISSION 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 controlcable 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 assyand 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)