Page 2606 of 5135
G23168
F08658
SST
G23167
32±62
±
BRAKE SKID CONTROL SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
7. INSTALL SKID CONTROL SENSOR
(a) Clean the contacting surface of the axle hub and that of a new skid control sensor.
NOTICE:
Make sure the sensor rotor is clean.
(b) Place the skid control sensor on the axle hub so that the connector comes into the most downward position under
the on vehicle condition.
(c) Using SST and a press, install the skid control sensor to the axle hub.
NOTICE:
Do not tap the skid control sensor directly with a ham-
mer.
Check that there is no foreign matter on the skid con-
trol sensor detection portion.
Press in the skid control sensor straight and slowly.
SST 09830±36010, 09950±60010 (09951±00650), 09950±70010 (09951±07100)
8.INSTALL REAR AXLE HUB & BEARING ASSY LH (See page 30±31)
9. INSTALL REAR BRAKE DRUM SUB±ASSY
(a) Aligning the matchmarks, install the rear disc.
10. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 47 N m (475 kgf cm, 34 ft lbf)
11. CONNECT SKID CONTROL SENSOR WIRE
(a) Connect the connector from the skid control sensor.
12. INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
13.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
14.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)
Page 2703 of 5135
D30342
D30341
BA
A
C81535
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
40±35
AVENSIS REPAIR MANUAL (RM1018E)
59. CONNECT CONNECTOR
(a) Connect the 2 clamps to the oil filler tube.
(b) Connect the transmission wire connector.
(c) Connect the park/neutral position switch connector.
(d) Connect the 2 speed sensor connectors.
60. INSTALL WIRE HARNESS
(a) Install the 2 wire harnesses and wire harness bracket with
the 3 bolts.
Torque:
Bolt A: 5.0 N m (51 kgf cm, 44 in. lbf)
Bolt B: 8.4 N m (86 kgf cm, 74 in. lbf)
61. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Temporarily install the control cable to the control shaft le- ver with nuts.
(b) Install the control cable and clip to the bracket.
62. INSTALL AIR CLEANER ASSY Torque: 5.0 N m (50 kgf cm, 44 in. lbf)
63. INSTALL BATTERY CARRIER Torque: 13 N m (132 kgf cm, 10 ft lbf)
64. INSTALL BATTERY
65. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
66. INSTALL HOOD SUB±ASSY
Torque: 13 N m (132 kgf cm, 10 ft lbf)
67.INSPECT HOOD SUB±ASSY (See page 75±2)
68.ADJUST HOOD SUB±ASSY (See page 75±2)
69. ADD COOLANT
(a)1AZ±FE (See pege 16±13)
(b)1AZ±FSE (See pege 16±25)
70. ADD AUTOMATIC TRANSAXLE FLUID
71.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
72.ADJUST SHIFT LEVER POSITION (See page 40±69)
73.INSPECT SHIFT LEVER POSITION (See page 40±69)
74.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
75. CHECK ABS SPEED SENSOR SIGNAL
Page 2717 of 5135
C91880
C91885
C81535
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
40±21
AVENSIS REPAIR MANUAL (RM1018E)
59. INSTALL WIRE HARNESS
(a) Install the wire harness and bolt.
Torque: 26 N m (265 kgf cm, 19 ft lbf)
(b) Install the wire harness clamp bracket and bolt. Torque: 5.0 N m (51 kgf cm, 44 in. lbff)
60. INSTALL TRANSMISSION CONTROL CABLE CLAMP
(a) Install the control cable support and bolt. Torque: 12 N m (122 kgf cm, 9 ft lbf)
(b) Connect the control cable and wire harness to the control cable support.
61. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Temporarily install the control cable to the control shaft le- ver with the nut.
(b) Install the control cable and clip to the bracket.
62. INSTALL AIR CLEANER ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
63. INSTALL BATTERY CARRIER Torque: 13 N m (131 kgf cm, 9 ft lbf)
64. INSTALL BATTERY
65. INSTALL ENGINE ROOM COVER SIDE
66. INSTALL RADIATOR SUPPORT OPENING COVER
67. INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
68. INSTALL HOOD SUB±ASSY Torque: 13 N m (133 kgf cm, 10 ft lbf)
69.INSPECT HOOD SUB±ASSY (See page 75±2)
70.ADJUST HOOD SUB±ASSY (See page 75±2)
71. ADD AUTOMATIC TRANSAXLE FLUID
72.ADD COOLANT (See page 16±1)
73.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
74.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
75.ADJUST SHIFT LEVER POSITION (See page 40±69)
76.INSPECT SHIFT LEVER POSITION (See page 40±69)
77.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
Page 2728 of 5135
D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±6
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09608±32010, 09950±70010 (09951±07200)
Drive in depth: 3.5 0.5 mm (0.138 0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts)
Torque: 49 N m (500 kgf cm, 36 ft lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
Page 2730 of 5135
D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±4
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 9.9 0.3 mm (0.390 0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
Torque: 39 N m (400 kgf cm, 29 ft lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
Page 2754 of 5135
D31074
SST
40±56
±
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
11. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Oil seal drive in depth:
0 0.5 mm (0 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
12.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
13.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
14. INSTALL FRONT WHEELS
15. ADD AUTOMATIC TRANSAXLE FLUID
16.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
17.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See Page 26±6)
18.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)
Page 2769 of 5135
4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26
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)
