2003 TOYOTA AVENSIS Insulator

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 CASE
PROTECTOR
(a) Remove the 2 bolts and case protector.
36. 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.
37. 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.
38. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket RR and 3 bolts to the transaxle.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
(b) Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
39. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
transaxle.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
(b) Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
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D30076
D25747
AB
C
BA
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 CASE PROTECTOR
(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 MOUNTING BRACKET
(a) Install the engine mounting bracket LH to the transaxle with the 3 bolt.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
43. 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 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)
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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 Clamp
Sub±assy
3.5 (36, 31 in.
lbf)
Battery
Battery Tray
Clip
Clip
Clip
Floor Shift Transmission
Control Cable Assy
Starter Assy
Starter Connector
Ground Cable
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)
Manual Transmission
Case 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
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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 ft
lbf)
(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 kgf
cm, 47 ft
lbf)
(b) Install the engine mounting insulator RR and bolt to the engine mounting bracket.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
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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 kgf
cm, 47 ft
lbf)
(b) Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
43. INSTALL MANUAL TRANSMISSION CASE PROTECTOR
(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 MOUNTING BRACKET
(a) Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
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 kgf
cm, 38 ft
lbf)
Bolt B: 80 N
m (816 kgf
cm, 59 ft
lbf)
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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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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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