Page 2793 of 5135
D30484
D30483
A
A
A
A
B
D11561
(a)
(c)
(b)(a)
G24210
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±19
AVENSIS REPAIR MANUAL (RM1018E)
39. 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)
40. 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)
41.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26) SST 09670±00010
42. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP) (See page 65±28)
43.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
44.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
45. INSTALL STARTER ASSY
(a) Install the starter assy and 2 bolts to the transaxle.Torque: 37 N m (380 kgf cm, 27 ft lbf)
(b) Connect the starter connector.
(c) Install the wire and nut to the starter assy.
Torque: 13 N m (130 kgf cm, 9 ft lbf)
46. 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.
Page 2794 of 5135
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 Nm (255 kgfcm, 18 ftlbf)
Bolt B: 14 Nm (141 kgfcm, 10 ftlbf)
Bolt C: 5.0 Nm (51 kgfcm, 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 Nm (260 kgfcm, 19 ftlbf)
Bolt B: 19 Nm (195 kgfcm, 14 ftlbf)
(b) Install the bolt and ground cable as shown in the illustra-
tion.
Torque:
Bolt A: 26 Nm (260 kgfcm, 19 ftlbf)
Bolt B: 40 Nm (410 kgfcm, 30 ftlbf)
Page 2795 of 5135
D30480
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±21
AVENSIS REPAIR MANUAL (RM1018E)
51. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts.
Torque: 13 N m (131 kgf cm, 9 ft lbf)
52. INSTALL BATTERY TRAY
53. INSTALL BATTERY
54. 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)
55. INSTALL AIR CLEANER ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
56. INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
57. INSTALL ENGINE ROOM COVER SIDE
58. INSTALL RADIATOR SUPPORT OPENING COVER
59. INSTALL HOOD SUB±ASSY Torque: 13 N m (133 kgf cm, 10 ft lbf)
60.INSPECT HOOD SUB±ASSY (See page 75±2)
61.ADJUST HOOD SUB±ASSY (See page 75±2)
62.ADD TRANSAXLE OIL (See page 41±3)
63.INSPECT TRANSAXLE OIL (See page 41±2)
64. INSTALL FRONT WHEELS
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
65.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
66.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
67.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
68.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
69. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
70. STEERING WHEEL CENTER POINT
71.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
72. INSTALL ENGINE UNDER COVER LH
73. INSTALL ENGINE UNDER COVER RH
74. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
75.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
Page 2796 of 5135
410DS±01
D30478
Battery Clamp Sub±assy
Battery Tray
Charcoal Canister Assy Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2
Starter AssyBack±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
ClipClip
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/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
Page 2797 of 5135
D30479
Front Drive Shaft Assy RH Snap Ring
Front Drive
Snap Ring
Transverse Engine
Engine Mounting BracketTransverse 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/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2798 of 5135
5100G±06
51±2
±
POWER STEERING POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help you find the cause of the problem. The numbers \
indicate the likelihood of the
cause in the descending order. Check each part in the order shown. Replace parts if necessary.
Hydraulic Power Steering System:
SymptomSuspect AreaSee page
Hard steering
3. Tires (Improperly inflated)
4. Power steering fluid level (Low)
5. Drive belt (Loose)
6. Front wheel alignment (Incorrect)
7. Steering system joints (Worn)
8. Suspension arm ball joints (Worn)
9. Steering column (Binding)
10.Power steering vane pump AZ Series: 1CD±FTV:
11. Power steering gear28±1
51±4
26±6 ±
26±24 ±
51±9
51±19 51±4
51±36
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gear28±1
26±6 ±
51±4
51±36
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear±
26±24 ±
30±2
51±4
51±36
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering vane pump AZ Series: 1CD±FTV:
4. Power steering gear51±4
±
51±9
51±19 51±4
51±36
Page 2799 of 5135
±
POWER STEERING POWER STEERING SYSTEM
51±3
AVENSIS REPAIR MANUAL (RM1018E)
Electronic Power Steering System:
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering system joints (Worn)
4. Suspension arm ball joints (Worn)
5. Steering column (Binding)
6. Steering column (Electric power steering system)
7. Steering gear (torque)28±1
26±6
±
26±24 ±
50±9
51±28
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Steering column (Electric power steering system)
5. Steering gear (torque)28±1
26±6 ±
50±9
51±28
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Steering column (Electric power steering system)
6. Steering gear (torque)±
26±24 ±
30±2
50±9
51±28
Abnormal noise
1. Steering system joints (Worn)
2. Steering column (Electric power steering system)
3. Steering gear (torque)±
50±9
51±28
HINT:
When the problem occurs on the Electric Power Steering system, refer to \
the DI section (See page 05±1042
).
Page 2800 of 5135
5100F±06
±
POWER STEERING POWER STEERING SYSTEM
51±1
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING SYSTEM
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Care must be taken to replace parts properly because they could affect the performance of the steering
system and result in a driving hazard.
2. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as \
the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence \
could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious acc\
ident. Before servicing (in-
cluding removal or installation of parts, inspection or replacement), be sure \
to read the precautionary
notices in the supplemental restraint system (See page 60±1).