Page 2777 of 5135
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 ft lbf)
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 kgf cm, 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)
Page 2778 of 5135

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/TRANSAXLEMANUAL TRANSAXLE ASSY (1CD±FTV)
41±31
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1CD±FTV)
COMPONENTS
Page 2779 of 5135
D30476
Front Drive Shaft Assy RH
Front Drive Shaft Assy LH
Snap Ring
Transverse Engine
Engine Mounting Bracket
Transverse Engine
Engine Mounting
Transverse Engine
Engine Mounting Bracket
64 (653, 47)
Cotter Pin
52 (530, 38)
Cotter Pin
49 (500, 36)8.0 (82, 71 in.lbf)
216 (2,203, 159)
Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque
Engine Under Cover RH
Engine Under Cover LH Transverse Engine
Engine Mounting Bracket
64 (650, 47)
64 (650, 47)
64 (653, 47)
87 (887, 64)
64 (653, 47)
49 (500, 36)
133 (1,356, 83)
45 (459, 33)
29 (296, 21)
52 (530, 38)
74 (755, 55)
74 (755, 55)
89 (908, 66)
133 (1,356, 83)
52 (530, 38)
89 (908, 66)
35.3 (360, 26)
41±32
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2780 of 5135

410DU±01
D30480
D30081
41±24
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL Torque: 49 N m (500 kgf cm, 36 ft lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER SUB±ASSY NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19.REMOVE STARTER ASSY (See page 19±12) 20. SEPARATE WIRE HARNESS
(a) Remove the 3 bolts, and separate the 3 wire harnesses.
Page 2781 of 5135
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
Page 2782 of 5135

D25745
No.1 Engine Hanger No.2 Engine Hanger
D30067
D30077
D25747
41±26
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
29. SUSPEND ENGINE ASSY
(a) Install the No.1 and No.2 engine hangers in the correct direction.
Parts No.:
No. 1 engine hanger: 12281±28010
No. 2 engine hanger: 12282±28010
Bolt: 91512±61020
Torque: 38 N m (387 kgf cm, 28 ft lbf)
(b) Attach the engine chain hoist to the engine hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
30.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26)
31. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the manual transaxle with a transmission jack. 32. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator LH.
33. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket.
34. REMOVE MANUAL TRANSAXLE ASSY
(a) Separate the wire harness clamp.
(b) Remove the 10 bolts.
(c) Separate and remove the transaxle from the engine.
Page 2783 of 5135

D30076
D30078
D30079
D30079
(a)
(a)
(a)
(b)
D30078
(a)
(b)
(b)
(a)
± MANUAL TRANSMISSION/TRANSAXLEMANUAL 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 Nm (653 kgfcm, 47 ftlbf)
(b) Install the engine mounting insulator RR and bolt to the
engine mounting bracket RR.
Torque: 87 Nm (887 kgfcm, 64 ftlbf)
39. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
transaxle.
Torque: 64 Nm (653 kgfcm, 47 ftlbf)
(b) Install the engine mounting insulator FR, bolt and nut to
the engine mounting bracket FR.
Torque: 52 Nm (530 kgfcm, 38 ftlbf)
Page 2784 of 5135

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)