Page 1209 of 2234

CL0672
D26804
D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:(1)
(1)
(1) (1)
(2)
(2)
±
CLUTCH CLUTCH 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 ftlbf)
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 ftlbf)
(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 ftlbf)
(2) Install the flexible hose tube with the bolt.
Torque: 12 N m (122 kgf cm, 9 ftlbf)
http://vnx.su
Page 1210 of 2234
D30814
D30487
SST(s)
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:SST(s)
42±20
±
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
13. INSTALL CLUTCH ACCUMULATOR ASSY (1CD±FTV ENGINE TYPE)
(a) Install the clutch accumulator assy with the 2 nuts and
bolt.
Torque: 12 N m (120 kgfcm, 9 ftlbf)
(b) Using SST(s), connect the 2 flexible hose tubes. SST 09023±00100
Torque: 15 N m (155 kgf cm, 11 ftlbf)
(c) Connect the wire harness clamp.
14. CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (EXCEPT 1CD±FTV ENGINE
TYPE)
(a) Using SST(s), connect the flexible hose tube. SST 09023±00100
Torque: 15 N m (155 kgf cm, 11 ftlbf)
15.INSTALL AIR TUBE NO.1 (1CD±FTV ENGINE TYPE) (See page 14±286)
16. INSTALL BATTERY (1CD±FTV ENGINE TYPE)
17. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the brake fluid and bleed clutch syst\
em. Torque: 8.3 N m (85 kgf cm, 73 in. lbf)
18. CHECK CLUTCH FLUID LEAKAGE
http://vnx.su
Page 1211 of 2234

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
http://vnx.su
Page 1212 of 2234
4206H±01
D26321
1ZZ±FE/3ZZ±FE Engine Type:Flywheel Sub±assy Clutch Disc Assy
Release hub grease
N m (kgf cm, ftlbf) : Specified torque
Non±reusable part
Clutch spline grease x6
Clutch Release
Bearing Assy Release Bearing
Hub Clip Clutch Release
Fork Sub±assy
Clutch Cover Assy Clutch Release Fork Boot
Release Fork Support
37 (375, 27)
19 (194, 14)
±
CLUTCH CLUTCH UNIT (MTM)
42±23
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH UNIT (MTM)
COMPONENTS
http://vnx.su
Page 1213 of 2234
D30056Release hub grease
Nm (kgf cm, ftlbf) : 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 Assy Release Bearing
Hub Clip
Clutch Release
Bearing Assy
Release Fork Support Clutch Release
Fork Boot
48 (480, 35)
19 (194, 14)
x6
42±24
±
CLUTCH CLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su
Page 1214 of 2234
D30057
1CD±FTV Engine Type:
Flywheel Sub±assy Clutch 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
Nm (kgf cm, ftlbf) : Specified torque
Non±reusable part
Clutch spline grease
±
CLUTCH CLUTCH UNIT (MTM)
42±25
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su
Page 1215 of 2234

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.
http://vnx.su
Page 1216 of 2234

C62956
D30058
1CD±FTV Engine Type:Others:
Transaxle Side
D25281
AB
C62958
±
CLUTCH CLUTCH UNIT (MTM)
42±27
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE CLUTCH DISC ASSY
NOTICE:
Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub±assy
away from oil and foreign attachment.
9. INSPECT CLUTCH DISC ASSY
(a) Using vernier calipers, measure the rivet head depth.Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assy as necessary.
(b) Install the clutch disc assy to the transaxle assy.
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
(c) Using a dial gage, check the clutch disc assy runout. Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assy as necessary.
10. INSPECT CLUTCH COVER ASSY
(a) Using vernier calipers, inspect the diaphragm spring for
the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assy as necessary.
11. INSPECT FLYWHEEL SUB±ASSY
(a) Using a dial gage, inspect the flywheel sub±assy runout. Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub±assy as necessary.
http://vnx.su