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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±27020
No.1 engine hanger UPR (black) 12284±27030
No.1 engine hanger 12281±27050
No.2 engine hanger (yellow) 12282±27060
No.2 engine hanger (black) 12282±27070
Bolt: 91642±81025
Torque: 37 N m (377 kgf cm, 27 ftlbf)
(b) Attach the engine chain hoist to the hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any 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 insulator LH from the body.
36. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from
the transaxle.
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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 CASE PROTECTOR
(a) Remove the 2 bolts and case protector.
39. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket.
(b) Remove the 2 bolts and engine mounting bracket FR from
the transaxle.
40. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR from the engine mounting bracket.
(b) Remove the 3 bolts and engine mounting bracket RR from the transaxle.
41. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket RR and 3 bolts to the
transaxle.
Torque: 64 N m (653 kgfcm, 47 ftlbf)
(b) Install the engine mounting insulator RR and bolt to the engine mounting bracket.
Torque: 87 N m (887 kgf cm, 64 ftlbf)
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D30074
(a)
(b)
(a)
(b)
D30076
D26918
AB
C 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 MOUNTING
BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
transaxle.
Torque: 64 N m (653 kgfcm, 47 ftlbf)
(b) Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket.
Torque: 52 N m (530 kgf cm, 38 ftlbf)
43. INSTALL MANUAL TRANSMISSION CASE PROTECTOR
(a) Install the case protector with the 2 bolts. Torque: 18 N m (184 kgf cm, 13 ftlbf)
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 kgfcm, 47 ftlbf)
Bolt B: 46 N m (469 kgfcm, 34 ftlbf)
Bolt C: 40 N m (408 kgfcm, 30 ftlbf)
Bolt D: 20 N m (200 kgfcm, 14 ftlbf)
Bolt E: 8.0 N m (82 kgf cm, 71 in. lbf)
45. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 64 N m (653 kgf cm, 47 ftlbf)
46. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Install the engine mounting insulator LH with the 5 bolts
and nut.
Torque:
Bolt A: 52 N m (530 kgfcm, 38 ftlbf)
Bolt B: 80 N m (816 kgfcm, 59 ftlbf)
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G24413
G24412
AB
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 kgfcm, 9 ftlbf)
Bolt B: 5.0 N m (51 kgfcm, 44 in. lbf)
Bolt C: 9.0 N m (92 kgfcm, 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.
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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 ftlbf)
(b) Install the air tube with bolt. Torque: 25 N m (255 kgf cm, 18 ftlbf)
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 ftlbf)
(c) Install the starter wire to starter assy with the nut. Torque: 13 N m (130 kgf cm, 9 ftlbf)
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 TRAY
63. INSTALL BATTERY
64. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N m (51 kgf cm, 44 in. lbf)
Nut: 3.5 N m (36 kgfcm, 31 in. lbf)
65. INSTALL AIR CLEANER ASSY
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
66. INSTALL ENGINE COVER NO.1 Torque: 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 AHEAD
72. STEERING WHEEL CENTER POINT
73. INSTALL ENGINE ROOM COVER SIDE
74. INSTALL RADIATOR SUPPORT OPENING COVER
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Page 1182 of 2234
41±40
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
75. INSTALL HOOD SUB±ASSY Torque: 13 N m (133 kgf cm, 10 ftlbf)
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 FLUID
81.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 kgfcm, 76 ft lbf)
85.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
86. INSTALL ENGINE UNDER COVER RH
87. INSTALL ENGINE UNDER COVER LH
88. 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)
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410DS±01
D30478
Battery Clamp Sub±assyBattery Tray
Charcoal Canister Assy
Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2 Starter Assy Back±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
Clip
Clip
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/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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Page 1184 of 2234
D30479
Front Drive Shaft Assy RH
Snap Ring
Front Drive
Snap Ring
Transverse Engine
Engine Mounting Bracket Transverse Engine
Engine Mounting Insulator
64 (653, 47)
87 (887, 64)Transverse Engine
Engine 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)
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