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.
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Page 1217 of 2234
Q01060
D30059
1CD±FTV Engine Type:Others:
Flywheel Side
SST(s)
D26323
SST(s)
Matchmarks
7
1 (Temporally), 4
3
6
2.5 8
D00205
SST(s)
42±28
±
CLUTCH CLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
12. INSPECT CLUTCH RELEASE BEARING ASSY
(a) Turn the release bearing by hand while applying force in the axial direction.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
Replace the release bearing assy as necessary.
13. INSTALL CLUTCH DISC ASSY
(a) Insert SST(s) in the clutch disc assy, then insert them in the flywheel sub±assy.
SST 09301±00220
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
14. INSTALL CLUTCH COVER ASSY
(a) Align matchmarks on the clutch cover assy and flywheel
sub±assy.
(b) Following the procedures shown in the illustration, tighten
the 6 bolts, in the order starting from the bolt located near
the knock pin on the top.
Torque: 19 N m (195 kgf cm, 14 ftlbf)
HINT:
Following the order in the illustration, tighten the bolts at
a time evenly.
Move SST(s) up and down, right and left lightly, after
checking that the disc is in the center, and then tighten the
bolts.
15. INSPECT AND ADJUST CLUTCH COVER ASSY
(a) Using a dial indicator with roller instrument, check the dia- phragm spring tip alignment.
Maximum non±alignment: 0.5 mm (0.020 in.)
If the alignment is not as specified, adjust the diaphragm spring
tip alignment using SST(s). SST 09333±00013
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Page 1419 of 2234
H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42627
L M
H42628
SST(s)
60±22
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
CAUTION:
When removing the horn button assy, work must be
started 90 seconds after the ignition switch is turned
to the ºLOCKº position and the negative (±) terminal
cable is disconnected from the battery.
When storing the horn button assy, keep the upper
surface of the airbag deployment side facing upward.
(c) Using a service±purpose wire harness for the vehicle, tie down the horn button assy to the disc wheel.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in2. or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the horn button assy, it may be snapped
by the shock when the airbag is deployed. This is highly
dangerous. Always use a wire harness for vehicle use
which has a diameter of at least 1.25 mm
2 (0.0019 in2).
HINT:
To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)
2 divided by 4
(1) Install the 2 bolts with washers in the 2 bolts holes of the horn button assy.
Bolt:
L: 35.0 mm (1.378 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:
Tighten the bolts by hand until the bolts become diffi-
cult to turn.
Do not tighten the bolts too much.
(2) After connecting the SST(s) below to each other, connect them to the horn button assy.
SST 09082±00802 (09082±10801, 09082±30801)
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Page 1420 of 2234
H42629
2 Times or more
H42630SST(s)
H42631
SST(s)
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
60±23
AVENSIS REPAIR MANUAL (RM1018E)
(3) Using 3 wire harnesses, wind each wire harness at
least 2 times each around the bolts installed on the
left and right sides of the horn button assy.
CAUTION:
Tightly wind the wire harness around the bolts so that
there is no slack.
If there is slack in the wire harness, the horn button
assy may become loose due to the shock when the
airbag is deployed. This is highly dangerous.
(4) Face the upper surface of the horn button assy up- ward. Separately tie the left and right sides of the
horn button assy to the disc wheel through the hub
nut holes. Position the SST(s) connector so that it
hangs downward through a hub hole in the disc
wheel.
CAUTION:
Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the horn button assy coming free due to the
shock from the airbag deployment.
Always tie down the horn button assy with the pad
side facing upward. It is highly dangerous if the horn
button assy is tied down with the metal surface facing
upward as the wire harness will be cut by the shock
caused by the airbag deployment and the horn button
assy will be thrown into the air.
NOTICE:
The disc wheel will be marked by the airbag deployment,
so use a redundant disc wheel.
(d) Install the SST(s).
CAUTION:
Place the disc wheel on the level ground.
(1) Connect the connector of the SST(s).
SST 09082±00700
NOTICE:
To avoid damaging the SST(s) connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST(s) wire harness inside the disc
wheel.
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