Page 2785 of 5135
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)
Page 2786 of 5135

D30080
41±30
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts. Torque: 13 N m (131 kgf cm, 9 ft lbf)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N m (51 kgf cm, 44 in. lbf)
Nut: 3.5 N m (36 kgf cm, 31 in. lbf)
59. INSTALL AIR CLEANER ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
60. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUB±ASSY Torque: 13 N m (132 kgf cm, 10 ft lbf)
64.INSPECT HOOD SUB±ASSY (See page 75±2)
65.ADJUST HOOD SUB±ASSY (See page 75±2)
66.ADD TRANSAXLE OIL (See page 41±5)
67.INSPECT TRANSAXLE OIL (See page 41±2)
68. INSTALL FRONT WHEELS
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
69.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
70.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page)See page 50±9)
71.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
72.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76.BLEED POWER STEERING FLUID (See page 51±4)
77.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
78.INSPECT FLUID LEAK (See page 51±4)
79.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
83.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
Page 2787 of 5135
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
Page 2788 of 5135
D30473
Front Drive Shaft Assy RH
Snap Ring
Transverse Engine
Engine Mounting Insulator
64 (653, 47)
87 (887, 64)
Cotter Pin
64 (653, 47)
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)
49 (500, 36)
89 (908, 66)
Transverse Engine
Engine Mounting Bracket
133 (1,356, 83)
52 (530, 38)89 (908, 66)
29 (296, 21)Transverse Engine
Engine Mounting Insulator
Transverse Engine
Engine Mounting Bracket
8.0 (82, 71 in.lbf)
74 (755, 55)
Front Drive Shaft Assy LH
64 (650, 47)
64 (650, 47)
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
41±23
AVENSIS REPAIR MANUAL (RM1018E)
Page 2789 of 5135

4105X±04
D30480
D30691
D30482
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±15
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: 39 N m (400 kgf cm, 29 ft lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE CYLINDER HEAD COVER NO.2
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. DISCONNECT WIRE HARNESS
(a) Remove the 3 bolts, disconnect the wire harness clamps.
(b) Remove the bolt, disconnect the ground cable.
Page 2790 of 5135
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)
Page 2791 of 5135

D25320
No.2 Engine Hanger
No.1 Engine Hanger
Front: Rear:
D30483
D30484
C70065
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±17
AVENSIS REPAIR MANUAL (RM1018E)
27. SUSPEND ENGINE ASSY
(a) Remove the 2 PCV hoses.
(b) Install the 2 hangers in the correct direction.
No.1 engine hanger: 12281±22021
No.2 engine hanger: 12281±15040
Bolt: 91512±B1016
Torque: 38 N m (387 kgf cm, 28 ft lbf)
(c) Attach the engine chain hoist to the hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
28. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
29.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY(See page 26±26)
30. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the transaxle with a transmission jack.
31. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator LH from the body.
32. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from the transaxle.
33. REMOVE MANUAL TRANSAXLE ASSY
(a) Remove the 6 bolts and transaxle from the engine.
Page 2792 of 5135

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 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)
37. 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)
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 Nm (653 kgfcm, 47 ftlbf)
Bolt B: 47 Nm (479 kgfcm, 35 ftlbf)
Bolt C: 23 Nm (230 kgfcm, 17 ftlbf)