2005 TOYOTA AVENSIS clutch

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 kgf
cm, 9 ft
lbf)
Bolt B: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Bolt C: 9.0 N
m (92 kgf
cm, 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.

D30066
D30064
G24413
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
41±25
AVENSIS REPAIR MANUAL (RM1018E)
21. SEPARATE CONNECTOR
(a) Separate the back±up lamp switch connector.
22. SEPARATE CLUTCH RELEASE CYLINDER ASSY
(a) Remove the 3 bolts and separate the release cylinder.
23. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the 2 cables from the trans-
axle.
(b) Remove the 2 clips, separate the 2 cables from the brack- et.
24.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
25.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
26. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
27.DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51±36) SST 09023±12700
28.DISCONNECT PRESSURE FEED TUBE ASSY (See page 51±36)
SST 09023±12700

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)

G24413
D30064
A
B
D30066
D30081
B
C
A
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
41±29
AVENSIS REPAIR MANUAL (RM1018E)
50. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Connect the 2 cable ends, install the 2 clips.
(b) Install the 2 clips to the control cable bracket.
51. INSTALL CLUTCH RELEASE CYLINDER ASSY
(a) Install the release cylinder with the 3 bolts.
Torque:
Bolt A: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
Bolt B: 12 N
m (120 kgf
cm, 9 ft
lbf)
52. CONNECT CONNECTOR
(a) Connect the back±up lamp switch connector.
53. CONNECT WIRE HARNESS
(a) Install the 3 wire harnesses with the 3 bolts. Torque:
Bolt A: 26 N
m (260 kgf
cm, 19 ft
lbf)
Bolt B: 8.4 N
m (85 kgf
cm, 74 in.
lbf)
Bolt C: 40 N
m (410 kgf
cm, 30 ft
lbf)
54.INSTALL STARTER ASSY (See page 19±12)

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

D30481
D30061
G24210
D11561
41±16
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
20. DISCONNECT CONNECTOR
(a) Disconnect the back±up lamp switch connector.
21. SEPARATE CLUTCH RELEASE CYLINDER ASSY
(a) Remove the 5 bolts, separate the release cylinder assy with clutch piping from the transaxle.
22. SEPARATE CHARCOAL CANISTER ASSY 23. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, disconnect the 2 cables from thetransaxle.
(b) Remove the 2 clips, disconnect the 2 cables from the con-
trol cable bracket.
24. REMOVE STARTER ASSY
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.
25.REMOVE FRONT DRIVE SHAFT ASSY LH(See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
26.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)

D30485
D30486
D30486(a)(a)
(b)
D30485
(a)
(b)
C70065
A
B
CC A
B 41±18
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
34. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FR
from the engine mounting bracket FR.
(b) Remove the 2 bolts and engine mounting bracket FR from
the transaxle.
35. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR from
the engine mounting bracket RR.
(b) Remove the 3 bolts and engine mounting bracket RR
from the transaxle.
36. 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)
37. 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)
38. INSTALL MANUAL TRANSAXLE ASSY
(a) Align the input shaft with the clutch disc and install the
transaxle to the engine.
(b) Install the 6 bolts.
Torque:
Bolt A: 64 N
m (653 kgf
cm, 47 ft
lbf)
Bolt B: 47 N
m (479 kgf
cm, 35 ft
lbf)
Bolt C: 23 N
m (230 kgf
cm, 17 ft
lbf)

D30061
A
B C
A
D30481

D30691
AA
B
D30482
A
B 41±20
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
47. CONNECT CHARCOAL CANISTER ASSY
48. CONNECT CLUTCH RELEASE CYLINDER ASSY
(a) Install the release cylinder with the 5 bolts.
Torque:
Bolt A: 25 N
m (255 kgf
cm, 18 ft
lbf)
Bolt B: 14 N
m (141 kgf
cm, 10 ft
lbf)
Bolt C: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
49. CONNECT CONNECTOR
(a) Connect the back±up lamp switch connector.
50. CONNECT WIRE HARNESS
(a) Install the 3 wire harness clamps to the transaxle with the
3 bolts.
Torque:
Bolt A: 26 N
m (260 kgf
cm, 19 ft
lbf)
Bolt B: 19 N
m (195 kgf
cm, 14 ft
lbf)
(b) Install the bolt and ground cable as shown in the illustra-
tion.
Torque:
Bolt A: 26 N
m (260 kgf
cm, 19 ft
lbf)
Bolt B: 40 N
m (410 kgf
cm, 30 ft
lbf)