Page 2825 of 5135

Q01060
D30059
1CD±FTV Engine Type: Others:
Flywheel Side
SST(s)
D26323
SST(s)
Matchmarks 7
1 (Temporally), 4
3
6
2.58
D00205
SST(s)
42±28
± CLUTCHCLUTCH 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 Nm (195 kgfcm, 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
Page 2826 of 5135

D26819
EXCEPT 1CD±FTV Engine Type:
1CD±FTV Engine Type:
Release Hub Grease
±
CLUTCH CLUTCH UNIT (MTM)
42±29
AVENSIS REPAIR MANUAL (RM1018E)
16. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the transaxle assy.
Torque:
1ZZ±FE/3ZZ±FE/1CD±FTV Engine Type: 37 N m (375 kgf cm, 27 ft lbf)
1AZ±FSE/1AZ±FE Engine Type: 47 N m (480 kgf cm, 35 ft lbf)
17. INSTALL RELEASE BEARING HUB CLIP
18. INSTALL CLUTCH RELEASE FORK SUB±ASSY
(a) Apply the release hub grease to the release fork and re-lease bearing assy contact, release fork and push rod
contact, and release fork pivot points.
Sealant:
Part No. 08887±01806, RELEASE HUB GREASE or
equivalent
(b) Install the release fork to the release bearing assy.
19. INSTALL CLUTCH RELEASE BEARING ASSY
(a) Apply the clutch spline grease to the input shaft spline. Sealant:
Part No. 08887±01706, CLUTCH SPLINE GREASE or equivalent
(b) Install the bearing to the release fork, and then install them to the tr\
ansaxle assy.
NOTICE:
After the installation, move the folk forward and backward to check that\
the release bearing slides
smoothly.
20. INSTALL CLUTCH RELEASE FORK BOOT
21. INSTALL 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)
Page 2827 of 5135
4206H±01
D26321
1ZZ±FE/3ZZ±FE Engine Type:
Flywheel Sub±assyClutch Disc Assy
Release hub grease
Nm (kgfcm, ftlbf) : Specified torque
Non±reusable part
Clutch spline greasex6
Clutch Release
Bearing Assy
Release Bearing
Hub ClipClutch Release
Fork Sub±assy
Clutch Cover Assy
Clutch Release Fork Boot Release Fork Support
37 (375, 27)
19 (194, 14)
± CLUTCHCLUTCH UNIT (MTM)
42±23
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH UNIT (MTM)
COMPONENTS
Page 2828 of 5135
D30056Release hub grease
Nm (kgfcm, ftlbf) : Specified torque
Non±reusable part
Clutch spline grease 1AZ±FSE/1AZ±FE Engine Type:
Flywheel Sub±assy
Clutch Disc Assy
Clutch Release
Fork Sub±assy Clutch Cover AssyRelease Bearing
Hub Clip Clutch Release
Bearing Assy
Release Fork Support
Clutch Release
Fork Boot
48 (480, 35)
19 (194, 14)
x6 42±24
± CLUTCHCLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
Page 2829 of 5135
D30057
1CD±FTV Engine Type:
Flywheel Sub±assyClutch Disc Assy
Clutch Release Fork Sub±assy Clutch Cover Assy
Release Bearing
Hub Clip Clutch Release
Bearing Assy
Release Fork Support
Clutch Release
Fork Boot
37 (375, 27)
19 (194, 14)
x6
Release hub grease
Nm (kgfcm, ftlbf) : Specified torque
Non±reusable part
Clutch spline grease
± CLUTCHCLUTCH UNIT (MTM)
42±25
AVENSIS REPAIR MANUAL (RM1018E)
Page 2830 of 5135

4206G±01
D30813
(a)
(a) (b)(b)
(a)
(b)
D30813
(a)
(a) (b)(b)
(a)
(b)
D26852
SST(s)
42±22
±
CLUTCH CLUTCH ACCUMULATOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE BATTERY
2.REMOVE AIR TUBE NO.1 (See page 14±286) 3. REMOVE CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), disconnect the flexible hose tube.SST 09023±00100
HINT:
Use a container to catch the fluid.
(b) Remove a bolt, 2 nuts and clutch accumulator assy.
4. INSTALL CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), connect the 2 flexible hose tubes to the clutch accumulator assy.
SST 09023±00100
(b) Install the clutch accumulator assy with the 2 nuts and a
bolt.
Torque: 12 N m (120 kgf cm, 9 ft lbf)
(c) Using SST(s), tighten the flexible hose tube. SST 09023±00100
Torque: 15 N m (155 kgf cm, 11 ft lbf)
5.INSTALL AIR TUBE NO.1 (See page 14±286)
6. INSTALL BATTERY
7. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the brake fluid and bleed clutch syst\
em. Torque: 8.3 N m (85 kgf cm, 73 in. lbf)
8. CHECK CLUTCH FLUID LEAKAGE
Page 2831 of 5135
4202Z±03
D30812
Clutch Accumulator Assy
Clutch Line
Wire Harness Clamp
Nm (kgfcm, ftlbf) : Specified torqueClutch Release Cylinder
Clutch Line
12 (120, 9)15 (155, 11)
15 (155, 11)
12 (120, 9)
Clutch Line
15 (155, 11)
± CLUTCHCLUTCH ACCUMULATOR ASSY (1CD±FTV)
42±21
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH ACCUMULATOR ASSY (1CD±FTV)
COMPONENTS
Page 2832 of 5135
4206F±01
D30487
SST(s)
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:SST(s)
D30814
±
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)
42±17
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
1. REMOVE BATTERY (1CD±FTV ENGINE TYPE)
2.REMOVE AIR TUBE NO.1 (1CD±FTV ENGINE TYPE) (See page 14±286)
3. DISCONNECT CLUTCH RELEASE CYLINDER TOFLEXIBLE HOSE TUBE (EXCEPT 1CD±FTV ENGINE
TYPE)
(a) Using SST(s), disconnect the flexible hose tube. SST 09023±00100
HINT:
Use a container to catch the fluid.
4. REMOVE CLUTCH ACCUMULATOR ASSY (1CD±FTV ENGINE TYPE)
(a) Disconnect the wire harness clamp.
(b) Using SST(s), disconnect the 2 flexible hose tubes. SST 09023±00100
HINT:
Use a container to catch the fluid.
(c) Remove the 2 nuts, bolt and clutch accumulator assy.