2002 TOYOTA AVENSIS hood release

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

750NB±01
B65104
AB ab 75±48
± ENGINE HOOD/DOORBACK DOOR STAY
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
Use the same procedures on the RH side as on the LH side.
1. DISPOSE OF BACK DOOR STAY ASSY LH
(a) Horizontally fix the stay in a vise with the piston±rod pulled
out.
(b) Wearing safety glasses, gradually cut a part between A
and B as shown in the illustration using a metal saw to
gradually release the gas.
Standard dimension:
a80 mm (3.15 in.)
b20 mm (0.80 in.)
NOTICE:
Although the gas inside the stay is colorless, odorless and
harmless, there is a possibility that metal debris from cut-
ting could be blown out. Therefore, cover it with clothes or
thr like.

B68928
Adhesive
B70122
Screw
B64044
1 2
± ENGINE HOOD/DOORFRONT DOOR
75±13
AVENSIS REPAIR MANUAL (RM1018E)
22. REMOVE FRONT DOOR WEATHERSTRIP LH
(a) Using a clip remover, disengage the clips and remove the weatherstrip.
HINT:
If the clips are damaged, replace them with new clips.
23. INSTALL FRONT DOOR CHECK ASSY LH
(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 nuts.
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(c) Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(d) Install the door check to the body panel with the bolt.
Torque: 30 N
m (306 kgf
cm, 22 in.
lbf)
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Install the outside handle link.
(b) Apply MP grease to the sliding areas of the frame.
(c) Using a torx socket wrench (T30), install the frame with
the screw.
Torque: 4.0 N
m (41 kgf
cm, 35 in.
lbf)
25. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH
(a) Install the outside handle pads front and rear.
(b) Install the handle pushing it in the direction of the arrow
mark in the illustration.
NOTICE:
If the release plate is not pulled and held when installing the
handle, the release plate will interfere with the handle and
become damaged.
26. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
door lock.
(b) Install a new door lock wire harness packing.
NOTICE:

When reusing a door lock that has been removed, re-
place the packing in the connecting part with a new
one.

Be careful that no grease or dirt does not sticks to the
packing surface in the connecting part.

Reusing removed packing or using damaged packing
will allow water to penetrate through to the connect-
ing part resulting in a door lock malfunction.

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 part
N´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/TRANSAXLEMANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS

410DS±01
D30478
Battery Clamp Sub±assy
Battery Tray
Charcoal Canister Assy Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2
Starter AssyBack±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
ClipClip
37 (380, 27)
Starter Connector
Transverse Engine
Engine 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/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS

030ND±02
± SERVICE SPECIFICATIONSMANUAL TRANSMISSION / TRANSAXLE
03±53
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
Floor shift transmission control cable assy x Body5.05144 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
FLOOR SHIFT SHIFT LEVER ASSY
Floor shift shift lever assy x Body121229
MANUAL TRANSAXLE ASSY (1ZZ±FE/ 3ZZ±FE)
Filler and drain plugs3940029
Engine hanger set bolt3838728
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
47
23650
480
23047
35
17
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Starter assy x Manual transaxle assy3738027
Starter wire set nut131309
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:
Bolt C:25
14
5.0250
141
2119
10
44 in.
lbf
Manual transaxle assy x Wire harness clmap Bolt A:
Bolt B:26
19260
19519
14
Manual transaxle assy x Ground cable Bolt A:
Bolt B:26
40260
41019
30
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head cover No.2 x Engine7.07162 in.
lbf
Hood set bolt1313310
MANUAL TRANSAXLE ASSY (1AZ±FE/ 1AZ±FSE)
Filler and drain plugs4950036
Engine hanger x Engine3838728
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Manual transaxle assy x Ground cable Bolt A:
Bolt C:26
40260
41019
30
Manual transaxle assy x Wire harness clamp8.48574 in.
lbf
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:9.0
1292
12080 in.
lbf
9