Manual Transmission & Transaxle

4110
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
FLOOR SHIFT SHIFT LEVER ASSY (MTM)

4105U03
COMPONENTS
Gasoline Engine: Front Floor Heat Insulator No.1
Console Panel Subassy Upper
Floor Shift Lever Knob Subassy
5.5 (56, 49 in.Vlbf)
Console Box Carpet
Console Panel Subassy Lower
Console Box Subassy Rear
Clip
Transmission Control Cable Assy
5.0 (51, 44 in.Vlbf)
12 (122, 9)
Clip
12 (122, 9)
Clip
5.0 (51, 44 in.Vlbf)
Nm (kgfcm, ftlbf) : Specified torque
Clip
Clip
Floor Shift Shift Lever Assy

D30489
AVENSIS REPAIR MANUAL (RM1018E)
4111
410DR01
REPLACEMENT
1. 2. 3. 4. REMOVE REMOVE REMOVE REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUBASSY (See page 7111) CONSOLE PANEL UPPER (See page 7111) CONSOLE PANEL SUBASSY LOWER (See page 7111) CONSOLE BOX ASSY REAR (See page 7111)
5. (a)
SEPARATE TRANSMISSION CONTROL CABLE ASSY Remove the 2 clips, separate the cable ends of the control cable assy.
D26893
(b)
Release the claws, separate the control cable assy.
D26895
6. (a)
REMOVE FLOOR SHIFT SHIFT LEVER ASSY Remove the 4 bolts and shift lever assy.
D30474
7. (a)
INSTALL FLOOR SHIFT SHIFT LEVER ASSY Install the shift lever assy with the 4 bolts. Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
D30474
4112
8. CONNECT TRANSMISSION CONTROL CABLE ASSY (a) Connect the control cable assy to the shift lever assy. NOTICE: Make sure that the claws are firmly engaged.
D26972
Serrate Part
(b)
Connect the end of the select cable to the shift lever assy, install the clip. NOTICE: S The serrate part of the select cable point should face upward when the select cable point is connected. S The clip should be inserted to the direction as shown in the illustration. (c) Connect the end of the shift cable to the shift lever assy.
D26894
413
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
FRONT DIFFERENTIAL OIL SEAL (C50/C250)

4104611
REPLACEMENT
1. 2. 3. 4. 5. 6. DRAIN MANUAL TRANSAXLE OIL Torque: 39 NVm (400 kgfVcm, 29 ftVlbf) REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT DRIVE SHAFT ASSY LH (See page 306) SST 0952001010, 0952024010 (0952032040) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 306) SST 0952001010, 0952024010 (0952032040)
7. (a)
REMOVE TRANSAXLE CASE OIL SEAL Using SST(s), remove the oil seal. SST 0930800010
SST(s)
C94266
8. (a)
REMOVE TRANSMISSION CASE OIL SEAL Using SST(s), remove the oil seal. SST 0930800010
SST(s)
D25305
SST(s)
D25722
INSTALL TRANSAXLE CASE OIL SEAL Coat a new oil seal lip with MP grease. Using SST(s) and a hammer, install the oil seal. SST 0955414010, 0995070010 (0995107200) Drive in depth: 1.9 " 0.3 mm (0.075 " 0.012 in.) NOTICE: Be careful not to damage the oil seal lip.
9. (a) (b)
414
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
SST(s)
INSTALL TRANSMISSION CASE OIL SEAL Coat a new oil seal lip with MP grease. Using SST(s) and a hammer, install the oil seal. SST 0955414010, 0995070010 (0995107200) Drive in depth: 9.9 " 0.3 mm (0.390 " 0.012 in.) NOTICE: Be careful not to damage the oil seal lip.
D26133
10. (a) (b)
11. 12. 13.
INSTALL FRONT DRIVE SHAFT ASSY LH (See page 306) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 306) INSTALL FRONT WHEELS Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) 14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL4 or GL5 Viscosity: SAE 75 W90 Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts) Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
0 to 5 mm (0 to 0.20 in.)
D25304
15. 16. 17. (a) (b)
INSPECT MANUAL TRANSAXLE OIL (See page 412) INSPECT FRONT WHEEL ALIGNMENT (See page 266) CHECK ABS SPEED SENSOR SIGNAL w/ VSC (See page 05756) w/o VSC (See page 05699)
415
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
FRONT DIFFERENTIAL OIL SEAL (E354/E357)

4104612
REPLACEMENT
1. 2. 3. 4. 5. 6. DRAIN MANUAL TRANSAXLE OIL Torque: 49 NVm (500 kgfVcm, 36 ftVlbf) REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH REMOVE FRONT DRIVE SHAFT ASSY LH (See page 306) SST 0952001010, 0952024010 (0952032040) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 306) SST 0952001010, 0952024010 (0952032040)
7. (a)
REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL Using SST(s), remove the oil seal. SST 0930800010
SST(s)
C94266
8. (a)
REMOVE TRANSMISSION CASE OIL SEAL Using SST(s), remove the oil seal. SST 0930800010
SST(s)
D25305
SST(s)
D25722
INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL (a) Coat a new oil seal lip with MP grease. (b) Using SST(s) and a hammer, install the oil seal. SST 0960810010, 0995070010 (0995107200) Drive in depth: 0 " 0.5 mm (0 " 0.020 in.) NOTICE: Be careful not to damage the oil seal lip.
9.
416
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
SST(s)
INSTALL TRANSMISSION CASE OIL SEAL Coat a new oil seal lip with MP grease. Using SST(s) and a hammer, install the oil seal. SST 0960832010, 0995070010 (0995107200) Drive in depth: 3.5 " 0.5 mm (0.138 " 0.020 in.) NOTICE: Be careful not to damage the oil seal lip.
D26133
10. (a) (b)
11. 12. 13.
INSTALL FRONT DRIVE SHAFT ASSY LH (See page 306) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 306) INSTALL FRONT WHEELS Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) 14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL4 or GL5 Viscosity: SAE 75 W90 Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts) Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
0 to 5 mm (0 to 0.20 in.)
D25304
15. 16. 17. (a) (b)
INSPECT MANUAL TRANSAXLE OIL (See page 412) INSPECT FRONT WHEEL ALIGNMENT (See page 266) CHECK ABS SPEED SENSOR SIGNAL w/ VSC (See page 05756) w/o VSC (See page 05699)
4122
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZFE/1AZFSE)
MANUAL TRANSAXLE ASSY (1AZFE/1AZFSE)

410DT01
COMPONENTS
13 (133, 10)
Hood Subassy
Air Cleaner Assy
Battery Clamp Subassy Engine Room Cover Side Radiator Support Opening Cover
5.0 (51, 44 in.Vlbf) 5.0 (51, 44 in.Vlbf)
Battery
9.0 (92, 80 in.Vlbf) 13 (131, 9)
Clip Clip Battery Tray

40 (410, 30)
Clip Clip
Engine Cover Subassy No.1

26 (260, 19)
Transmission Control Cable Assy Transverse Engine Engine Mounting Insulator

64 (653, 47) 64 (653, 47) 52 (530, 38)
Backup Lamp Switch Connector
46 (469, 34) 80 (816, 59) 44 (449, 32) 46 (469, 34)
Clutch Release Cylinder Assy

18 (184, 13)
52 (530, 38) 8.4 (85, 74 in.Vlbf)
12 (120, 9)
13 (130, 9)
Starter Connector
9.0 (92, 80 in.Vlbf) 44 (449, 32) 46 (469, 34)
Starter Assy
37 (380, 27)
D30082
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part
Manual Transaxle Assy
4123
Front Drive Shaft Assy RH
64 (650, 47)
Front Drive Shaft Assy LH z Snap Ring

64 (650, 47)
Transverse Engine Engine Mounting Bracket
64 (653, 47)
Transverse Engine Engine Mounting Insulator Transverse Engine Engine Mounting Bracket
74 (755, 55) 52 (530, 38) 87 (887, 64) 64 (653, 47)
z Cotter Pin
35 (360, 26)
z Cotter Pin
64 (653, 47) 49 (500, 36) 49 (500, 36)
74 (755, 55) 8.0 (82, 71 in.Vlbf)
89 (908, 66)
45 (459, 33)
52 (530, 38)
89 (908, 66)
216 (2,203, 159)
Transverse Engine Engine Mounting Insulator
29 (296, 21) 133 (1,356, 83) 133 (1,356, 83)
Engine Under Cover LH
Engine Under Cover RH
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

D30473
4124
410DU01
REPLACEMENT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. INSPECT CENTER FRONT WHEEL REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 509) SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509) REMOVE STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page 509) REMOVE STEERING INTERMEDIATE SHAFT (See page 509) REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER LH REMOVE ENGINE UNDER COVER RH DRAIN TRANSAXLE OIL Torque: 49 NVm (500 kgfVcm, 36 ftVlbf) REMOVE HOOD SUBASSY REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE COVER SUBASSY NO.1 REMOVE AIR CLEANER ASSY REMOVE BATTERY CLAMP SUBASSY REMOVE BATTERY REMOVE BATTERY TRAY 18. (a) REMOVE BATTERY CARRIER Remove the 4 bolts and battery carrier.
D30480
19.
REMOVE STARTER ASSY (See page 1912)
20. (a)
SEPARATE WIRE HARNESS Remove the 3 bolts, and separate the 3 wire harnesses.
D30081
4125
21. (a)
SEPARATE CONNECTOR Separate the backup lamp switch connector.
D30066
22. (a)
SEPARATE CLUTCH RELEASE CYLINDER ASSY Remove the 3 bolts and separate the release cylinder.
D30064
23. (a) (b)
SEPARATE TRANSMISSION CONTROL CABLE ASSY Remove the 2 clips, separate the 2 cables from the transaxle. Remove the 2 clips, separate the 2 cables from the bracket.
G24413
24. 25. 26. 27. 28.
REMOVE FRONT DRIVE SHAFT ASSY LH (See page 306) SST 0952001010, 0952024010 (0952032040) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 306) REMOVE HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP) (See page 6528) DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136) SST 0902312700 DISCONNECT PRESSURE FEED TUBE ASSY (See page 5136) SST 0902312700
4126
No.1 Engine Hanger No.2 Engine Hanger
30. 31. (a)
SUSPEND ENGINE ASSY Install the No.1 and No.2 engine hangers in the correct direction. Parts No.: No. 1 engine hanger: 1228128010 No. 2 engine hanger: 1228228010 Bolt: 9151261020 Torque: 38 NVm (387 kgfVcm, 28 ftVlbf) (b) Attach the engine chain hoist to the engine hanger. D25745 CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. REMOVE FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626) SUPPORT MANUAL TRANSAXLE ASSY 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.
29. (a)
D30067
33. (a)
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 3 bolts and engine mounting bracket.
D30077
34. (a) (b) (c)
REMOVE MANUAL TRANSAXLE ASSY Separate the wire harness clamp. Remove the 10 bolts. Separate and remove the transaxle from the engine.
D25747
4127
35. (a)
REMOVE MANUAL TRANSMISSION PROTECTOR Remove the 2 bolts and case protector.
CASE
D30076
36. (a) (b)
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket. Remove the 2 bolts and engine mounting bracket FR from the transaxle.
D30078
37. (a) (b)
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the bolt and engine mounting insulator RR from the engine mounting bracket. Remove the 3 bolts and engine mounting bracket RR from the transaxle.
D30079
38.
(a) (a) (b) (a)
(a)
(b)
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket RR and 3 bolts to the transaxle. Torque: 64 NVm (653 kgfVcm, 47 ftVlbf) Install the engine mounting insulator RR and bolt to the engine mounting bracket RR. Torque: 87 NVm (887 kgfVcm, 64 ftVlbf)
D30079
39.
(a) (a) (b)
(a)
(b)
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket FR and 2 bolts to the transaxle. Torque: 64 NVm (653 kgfVcm, 47 ftVlbf) Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR. Torque: 52 NVm (530 kgfVcm, 38 ftVlbf)
(b)
D30078
4128
40. (a)
INSTALL MANUAL TRANSMISSION PROTECTOR Install the case protector with the 2 bolts. Torque: 18 NVm (184 kgfVcm, 13 ftVlbf)
CASE
D30076
A B
41. (a) (b)
C B
D25747
(c) 42. (a)
INSTALL MANUAL TRANSAXLE ASSY Align the input shaft with the clutch disc and install the transaxle to the engine. Install the 10 bolts. Torque: Bolt A: 64 NVm (653 kgfVcm, 47 ftVlbf) Bolt B: 46 NVm (469 kgfVcm, 34 ftVlbf) Bolt C: 44 NVm (449 kgfVcm, 32 ftVlbf) Connect the wire harness clamp. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket LH to the transaxle with the 3 bolt. Torque: 64 NVm (653 kgfVcm, 47 ftVlbf)
D30077
43. (a)
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Install the engine mounting insulator LH with the 5 bolts and nut. Torque: Bolt A: 52 NVm (530 kgfVcm, 38 ftVlbf) Bolt B: 80 NVm (816 kgfVcm, 59 ftVlbf)
D30067
44. 45. 46. 47. 48. 49.
INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626) SST 0967000010 CONNECT PRESSURE FEED TUBE ASSY (See page 5136) SST 0902312700 CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136) SST 0902312700 INSTALL HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP) (See page 6528) INSTALL FRONT DRIVE SHAFT ASSY LH (See page 306) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 306)
4129
50. (a) (b)
INSTALL TRANSMISSION CONTROL CABLE ASSY Connect the 2 cable ends, install the 2 clips. Install the 2 clips to the control cable bracket.
G24413
51. (a)
INSTALL CLUTCH RELEASE CYLINDER ASSY Install the release cylinder with the 3 bolts. Torque: Bolt A: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) Bolt B: 12 NVm (120 kgfVcm, 9 ftVlbf)
A
D30064
52. (a)
CONNECT CONNECTOR Connect the backup lamp switch connector.
D30066
53. (a)
C A
CONNECT WIRE HARNESS Install the 3 wire harnesses with the 3 bolts. Torque: Bolt A: 26 NVm (260 kgfVcm, 19 ftVlbf) Bolt B: 8.4 NVm (85 kgfVcm, 74 in.Vlbf) Bolt C: 40 NVm (410 kgfVcm, 30 ftVlbf)
D30081
54.
INSTALL STARTER ASSY (See page 1912)
4130
55. (a)
INSTALL BATTERY CARRIER Install the battery carrier and 4 bolts. Torque: 13 NVm (131 kgfVcm, 9 ftVlbf)
D30080
56. 57. 58.
59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. (a) (b) 83.
INSTALL BATTERY TRAY INSTALL BATTERY INSTALL BATTERY CLAMP SUBASSY Torque: Bolt: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) Nut: 3.5 NVm (36 kgfVcm, 31 in.Vlbf) INSTALL AIR CLEANER ASSY Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) INSTALL ENGINE COVER SUBASSY NO.1 Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER INSTALL HOOD SUBASSY Torque: 13 NVm (132 kgfVcm, 10 ftVlbf) INSPECT HOOD SUBASSY (See page 752) ADJUST HOOD SUBASSY (See page 752) ADD TRANSAXLE OIL (See page 415) INSPECT TRANSAXLE OIL (See page 412) INSTALL FRONT WHEELS Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) INSTALL STEERING INTERMEDIATE SHAFT (See page 509) INSTALL STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page)See page 509) INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509) INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 509) PLACE FRONT WHEELS FACING STRAIGHT AHEAD STEERING WHEEL CENTER POINT ADD POWER STEERING FLUID BLEED POWER STEERING FLUID (See page 514) CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 514) INSPECT FLUID LEAK (See page 514) INSPECT FRONT WHEEL ALIGNMENT (See page 266) INSTALL ENGINE UNDER COVER LH INSTALL ENGINE UNDER COVER RH CHECK ABS SPEED SENSOR SIGNAL w/ VSC (See page 05756) w/o VSC (See page 05699) HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 6519)
4131
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CDFTV)
MANUAL TRANSAXLE ASSY (1CDFTV)

410DV01
COMPONENTS
13 (133, 10)
Hood Subassy
Air Cleaner Assy
Engine Room Cover Side

7.0 (71, 62 in.Vlbf) 6.0 (61, 53 in.Vlbf) 13 (133, 10) 5.0 (51, 44 in.Vlbf)
Radiator Support Opening Cover Radiator Reserve Tank Assy

25 (255, 18) 3.5 (36, 31 in.Vlbf) 8.0 (82, 71 in.Vlbf)
Battery Air Tube No.1 Battery Tray Engine Cover No.1

25 (255, 18)
Battery Clamp Subassy Floor Shift Transmission Control Cable Assy Clip Clip Clip
64 (653, 47) 37 (380, 27)
Starter Assy
13 (130, 9)
Ground Cable
13 (131, 9) 64 (653, 47)
Clip
52 (530, 38)
46 (469, 34)
80 (816, 59) 64 (653, 47)
Starter Connector
20 (200, 14) 52 (530, 38) 8.0 (82, 71 in.Vlbf) 12 (120, 9) 40 (408, 30) 12 (120, 9) 40 (408, 30) 18 (184, 13) 64 (653, 47) 9.0 (92, 80 in.Vlbf) 5.0 (51, 44 in.Vlbf)
Manual Transmission Case Protector
Manual Transaxle Assy Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

D30475
4132
Front Drive Shaft Assy RH

64 (650, 47)
Front Drive Shaft Assy LH z Snap Ring

64 (650, 47)
64 (653, 47)
Transverse Engine Engine Mounting Transverse Engine Engine Mounting Bracket

74 (755, 55) 52 (530, 38) 35.3 (360, 26)
87 (887, 64) 64 (653, 47)
z Cotter Pin
64 (653, 47) 49 (500, 36)
z Cotter Pin
49 (500, 36)
74 (755, 55) 8.0 (82, 71 in.Vlbf)
89 (908, 66)
45 (459, 33)
52 (530, 38) 52 (530, 38)
89 (908, 66)
z
29 (296, 21)
216 (2,203, 159)
133 (1,356, 83)
133 (1,356, 83)
Engine Under Cover RH Engine Under Cover LH Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part
D30476
4133
410DY01
REPLACEMENT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. INSPECT CENTER FRONT WHEEL REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 509) SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509) REMOVE STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page 509) REMOVE STEERING INTERMEDIATE SHAFT (See page 509) REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER RH REMOVE ENGINE UNDER COVER LH DRAIN TRANSAXLE OIL Torque: 49 NVm (500 kgfVcm, 36 ftVlbf) REMOVE HOOD SUBASSY REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE COVER NO.1 REMOVE AIR CLEANER ASSY REMOVE BATTERY CLAMP SUBASSY REMOVE BATTERY REMOVE BATTERY TRAY REMOVE AIR TUBE NO.1 (See page 14286)
19. (a)
SEPARATE RADIATOR RESERVE TANK ASSY Remove the 2 bolts, separate the radiator reserve tank assy.
D26902
20. (a) (b) (c)
REMOVE STARTER ASSY Remove the nut, disconnect the starter wire. Disconnect the connector. Remove the 2 bolts and starter assy.
D26903
4134
21. (a) (b)
DISCONNECT WIRE HARNESS Remove the bolt, disconnect the ground cable. Remove the bolt, separate the air tube.
D30815
22. (a)
DISCONNECT CONNECTOR Disconnect the backup lamp switch connector.
D26905
23. 24.
REMOVE CLUTCH ACCUMULATOR ASSY (See page 4222) SST 0902300100 REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 4217) SST 0902300100 25. (a) SEPARATE ACCUMULATOR TO FLEXIBLE HOSE TUBE Remove the 3 bolts, separate the flexible hose tube with brackets from the transaxle.
G24412
26. (a) (b)
SEPARATE TRANSMISSION CONTROL CABLE ASSY Remove the 2 clips, separate the 2 cables from the transaxle. Remove the 2 clips, separate the 2 cables from the bracket.
G24413
27. 28. 29.
REMOVE FRONT DRIVE SHAFT ASSY LH (See page 306) SST 0952001010, 0952024010 (0952032040) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 306) REMOVE HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP) (See page 6528)
4135
30. 31.
DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136) SST 0902312700 DISCONNECT PRESSURE FEED TUBE ASSY (See page 5136) SST 0902312700 SUSPEND ENGINE ASSY Install the 2 engine hangers with the 2 bolts. Parts No.: No.1 engine hanger UPR (yellow) 1228427020 No.1 engine hanger UPR (black) 1228427030 No.1 engine hanger 1228127050 No.2 engine hanger (yellow) 1228227060 Engine Hanger No.2 No.2 engine hanger (black) 1228227070 Engine Hanger No.1 Bolt: 9164281025 A79193 Torque: 37 NVm (377 kgfVcm, 27 ftVlbf) (b) Attach the engine chain hoist to the hanger. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. REMOVE FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626) SUPPORT MANUAL TRANSAXLE ASSY Support the transaxle with a transmission jack.
Engine Hanger No.1 UPR
32. (a)
33. 34. (a)
35. (a)
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Remove the 5 bolts, nut and engine mounting insulator LH from the body.
D30072
36. (a)
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 3 bolts and engine mounting bracket LH from the transaxle.
D30073
4136
37. (a) (b)
REMOVE MANUAL TRANSAXLE ASSY Remove the 8 bolts. Remove the transaxle from the engine.
D26918
38. (a)
REMOVE MANUAL TRANSMISSION PROTECTOR Remove the 2 bolts and case protector.
CASE
D30076
39. (a) (b)
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket. Remove the 2 bolts and engine mounting bracket FR from the transaxle.
D30074
40. (a) (b)
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the bolt and engine mounting insulator RR from the engine mounting bracket. Remove the 3 bolts and engine mounting bracket RR from the transaxle.
D30075
41.
(b) (a) (a) (a)
(a)
(b)
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket RR and 3 bolts to the transaxle. Torque: 64 NVm (653 kgfVcm, 47 ftVlbf) Install the engine mounting insulator RR and bolt to the engine mounting bracket. Torque: 87 NVm (887 kgfVcm, 64 ftVlbf)
D30075
4137
42.
(a)
(a)
(a) (b) (b)
D30074
(b)
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket FR and 2 bolts to the transaxle. Torque: 64 NVm (653 kgfVcm, 47 ftVlbf) Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket. Torque: 52 NVm (530 kgfVcm, 38 ftVlbf)
43. (a)
INSTALL MANUAL TRANSMISSION PROTECTOR Install the case protector with the 2 bolts. Torque: 18 NVm (184 kgfVcm, 13 ftVlbf)
CASE
D30076
44. (a) (b)

D B
C E
D26918
45. (a)
INSTALL MANUAL TRANSAXLE ASSY Align the input shaft with the clutch disc and install the transaxle to the engine. Install the 8 bolts. Torque: Bolt A: 64 NVm (653 kgfVcm, 47 ftVlbf) Bolt B: 46 NVm (469 kgfVcm, 34 ftVlbf) Bolt C: 40 NVm (408 kgfVcm, 30 ftVlbf) Bolt D: 20 NVm (200 kgfVcm, 14 ftVlbf) Bolt E: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket LH to the transaxle with the 3 bolts. Torque: 64 NVm (653 kgfVcm, 47 ftVlbf)
D30073
A A
46. (a)
A B A
D30072
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Install the engine mounting insulator LH with the 5 bolts and nut. Torque: Bolt A: 52 NVm (530 kgfVcm, 38 ftVlbf) Bolt B: 80 NVm (816 kgfVcm, 59 ftVlbf)
4138
47. 48. 49. 50. 51. 52.
INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626) SST 0967000010 CONNECT PRESSURE FEED TUBE ASSY (See page 5136) SST 0902312700 CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136) SST 0902312700 INSTALL HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP) (See page 6528) INSTALL FRONT DRIVE SHAFT ASSY LH (See page 306) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 306) 53. 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.
G24413
54. (a)
A B
INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE Install the flexible hose tube with the 3 bolts. Torque: Bolt A: 12 NVm (120 kgfVcm, 9 ftVlbf) Bolt B: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) Bolt C: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
G24412
55. 56.
INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 4217) SST 0902300100 INSTALL CLUTCH ACCUMULATOR ASSY (See page 4222) SST 0902300100 57. (a) CONNECT CONNECTOR Connect the backup lamp switch connector.
D26905
4139
58. (a)
(b) (a)
(b)
CONNECT WIRE HARNESS Install the ground cable with bolt. Torque: 13 NVm (131 kgfVcm, 9 ftVlbf) Install the air tube with bolt. Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
D30815
59. (a) (b) (c)
INSTALL STARTER ASSY Connect the starter connector. Install the starter assy to the transaxle with the 2 bolts. Torque: 37 NVm (380 kgfVcm, 27 ftVlbf) Install the starter wire to starter assy with the nut. Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
D26903
60. (a)
CONNECT RADIATOR RESERVE TANK ASSY Install the radiator reserve tank assy with the 2 bolts. Torque: 6.0 NVm (61 kgfVcm, 53 in.Vlbf)
D26902
61. 62. 63. 64.
65. 66. 67. 68. 69. 70. 71. 72. 73. 74.
INSTALL AIR TUBE NO.1 (See page 14286) INSTALL BATTERY TRAY INSTALL BATTERY INSTALL BATTERY CLAMP SUBASSY Torque: Bolt: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) Nut: 3.5 NVm (36 kgfVcm, 31 in.Vlbf) INSTALL AIR CLEANER ASSY Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf) INSTALL ENGINE COVER NO.1 Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) INSTALL STEERING INTERMEDIATE SHAFT (See page 509) INSTALL STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page 509) INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509) INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 509) PLACE FRONT WHEELS FACING STRAIGHT AHEAD STEERING WHEEL CENTER POINT INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER
4140
75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. (a) (b) 89.
INSTALL HOOD SUBASSY Torque: 13 NVm (133 kgfVcm, 10 ftVlbf) INSPECT HOOD SUBASSY (See page 752) ADJUST HOOD SUBASSY (See page 752) ADD TRANSAXLE OIL (See page 415) INSPECT TRANSAXLE OIL (See page 412) ADD POWER STEERING FLUID BLEED POWER STEERING FLUID (See page 514) CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 514) INSPECT FLUID LEAK (See page 514) INSTALL FRONT WHEELS Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) INSPECT FRONT WHEEL ALIGNMENT (See page 266) INSTALL ENGINE UNDER COVER RH INSTALL ENGINE UNDER COVER LH CHECK ABS SPEED SENSOR SIGNAL w/ VSC (See page 05756) w/o VSC (See page 05699) HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 6519)
4113
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZFE/3ZZFE)
MANUAL TRANSAXLE ASSY (1ZZFE/3ZZFE)

410DS01
COMPONENTS
13 (133, 10)
Air Cleaner Assy Hood Subassy
Battery Clamp Subassy

5.0 (51, 44 in.Vlbf)
Engine Room Cover Side Radiator Support Opening Cover

13 (131, 9) 5.0 (51, 44 in.Vlbf)
Clip
Battery Battery Tray Battery Carrier
7.0 (71, 62 in.Vlbf)
26 (260, 19)
Charcoal Canister Assy Clip Clip
Clip Clip
Cylinder Head Cover No.2

23 (230, 17)
Backup Lamp SwitchConnector Transmission Control Cable Assy
Starter Connector Starter Assy

23 (230, 17) 47 (479, 35)
19 (195, 14)
64 (653, 47)

52 (530, 38)
37 (380, 27) 13 (130, 9) 37 (380, 27) 52 (530, 38)
Filler Plug
39 (400, 29)
40 (410, 30) 64 (653, 47) 80 (816, 59) 64 (653, 47) 25 (255, 18)
z Gasket
26 (260, 19) 14 (141, 10)
Manual Transaxle Assy Ground Cable
5.0 (51, 44 in.Vlbf)
Clutch Release Cylinder Assy Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

D30478
4114
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZFE/3ZZFE)
z Snap Ring Front Drive z Snap Ring Front Drive Shaft Assy RH
64 (653, 47)
Transverse Engine Engine Mounting Bracket Transverse Engine Engine Mounting Bracket
52 (530, 38) 74 (755, 55)

87 (887, 64) 64 (653, 47)
z Cotter Pin
35 (360, 26)
z Cotter Pin
64 (653, 47) 49 (500, 36) 49 (500, 36)
74 (755, 55) 8.0 (82, 71 in.Vlbf)
89 (908, 66)
45 (459, 33)
52 (530, 38)
29 (296, 21) 89 (908, 66)
216 (2,203, 159)
133 (1,356, 83)
133 (1,356, 83)
Engine Under Cover LH
Engine Under Cover RH Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

D30479
412
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE OIL (MTM)
MANUAL TRANSAXLE OIL (MTM)

4100Z05
ONVEHICLE INSPECTION
1. (a) (b) (c) INSPECT TRANSAXLE OIL Stop the vehicle on the level place. Remove the transmission filler plug and gasket. Check that the oil surface is within 5 mm (0.20 in.) from the lowest position of the inner surface of the transmission filler plug opening. NOTICE: S Excessively large or small amount of oil may cause troubles. S After replacing oil, drive the vehicle and check the oil level. (d) Check for oil leakage when the oil level is low. (e) Install the transmission filler plug and new gasket. Torque: C50, C250: 39 NVm (400 kgfVcm, 29 ftVlbf) E354, E357: 49 NVm (500 kgfVcm, 36 ftVlbf)
0 to 5 mm (0 to 0.20 in.)
D25304
411
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM (MTM)
MANUAL TRANSAXLE SYSTEM (MTM)

4100Y05
PROBLEM SYMPTOMS TABLE

Use the table below to help find the cause of the problem. The numbers indicate the likelihood of the possible cause in descending order. Check each part in the order shown. Replace these parts as necessary. L: (C50 MANUAL TRANSAXLE Repair Manual Pub. No. 826E or C250 MANUAL TRANSAXLE Repair Manual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E)
Symptom 6. Oil (Level low) 7. Oil (Wrong) Noise 8. Gear (Worn or damaged) 9. Bearing (Worn or damaged) 1. Oil (Level too high) 2. Gasket (Damaged) 3. Oil seal (Worn or damaged) 4. ORing (Worn or damaged) 1. Control cable (Faulty) 2. Synchronizer ring (Worn or damaged) 3. Shift key spring (Damaged) 1. 2. 3. 4. Locking ball spring (Damaged) Shift fork (Worn) Gear (Worn or damaged) Bearing (Worn or damaged) Suspect Area See page 412 413 415 L L 412 L 413 415 L 417 L L L L L L
C50/C250 E354/E357
Oil leakage
C50/ C250 E354/E357
Hard to shift or will not shift
Jumps out of gear
417
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
TRANSMISSION CONTROL CABLE ASSY (MTM)

4105R02
REPLACEMENT
HINT: COMPONENTS: See page 4110 1. REMOVE AIR CONDITIONER UNIT ASSY (See page 5555) HINT: Refer to the instructions for removal of the instrument panel subassy lower. 2. REMOVE EXHAUST PIPE ASSY (a) 1ZZFE, 3ZZFE Engine (See page 152) (b) 1AZFE, 1AZFSE Engine (See page 157) (c) 1CDFTV Engine (See page 1510) 3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE) (a) Remove the 3 nuts and heat insulator No.1.
1ZZFE, 3ZZFE:
4. (a) (b)
REMOVE TRANSMISSION CONTROL CABLE ASSY Remove the 2 clips, separate the 2 cables from the transaxle. Remove the 2 clips, separate the 2 cables from the bracket.
1AZFE, 1AZFSE, 1CDFTV:
D30060
(c)
Remove the 2 nuts, separate the control cable assy.
D30070
418
(d)
Remove the 2 bolts, separate the control cable assy.
D30071
(e)
Remove the 2 clips, separate the cable ends of the control cable assy.
D26893
(f)
Release the claws, remove the control cable assy.
D26895
5. (a) (b)
INSTALL TRANSMISSION CONTROL CABLE ASSY Put the control cable assy through the floor hole. Install the control cable assy with the 2 bolts. Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
D30071
(c) Connect the control cable assy to the shift lever assy. NOTICE: Make sure that the claws are firmly engaged.
D26972
419
Serrate Part
(d)
Connect the end of the select cable to the shift lever assy and install the clip. NOTICE: S The serrate part of the select cable point should face upward when the select cable point is connected. S The clip should be inserted to the direction as shown in the illustration. (e) Connect the end of the shift cable to the shift lever assy.
D26894
(f)
Connect the control cable assy with the 2 nuts. Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
D30070
1ZZFE, 3ZZFE:
(g) (h)
Connect the 2 cable ends, install the 2 clips. Install the 2 clips to the control cable bracket.
1AZFE, 1AZFSE, 1CDFTV:
D30060
6. (a) 7. (a) (b) (c)
INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE) Install the heat insulator No.1 with the 3 nuts. Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf) INSTALL EXHAUST PIPE ASSY 1ZZFE, 3ZZFE Engine (See page 152) 1AZFE, 1AZFSE Engine (See page 157) 1CDFTV Engine (See page 1510)

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4110

MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)

FLOOR SHIFT SHIFT LEVER ASSY (MTM)

Gasoline Engine: Front Floor Heat Insulator No.1

Console Panel Subassy Upper

Floor Shift Lever Knob Subassy

5.5 (56, 49 in.Vlbf)

Console Box Carpet

Console Panel Subassy Lower

Console Box Subassy Rear

Transmission Control Cable Assy

5.0 (51, 44 in.Vlbf)

Nm (kgfcm, ftlbf) : Specified torque

Floor Shift Shift Lever Assy

AVENSIS REPAIR MANUAL (RM1018E)

Release the claws, separate the control cable assy.

AVENSIS REPAIR MANUAL (RM1018E)

AVENSIS REPAIR MANUAL (RM1018E)

FRONT DIFFERENTIAL OIL SEAL (C50/C250)

AVENSIS REPAIR MANUAL (RM1018E)

10. (a) (b)

11. 12. 13.

15. 16. 17. (a) (b)

AVENSIS REPAIR MANUAL (RM1018E)

FRONT DIFFERENTIAL OIL SEAL (E354/E357)

AVENSIS REPAIR MANUAL (RM1018E)

10. (a) (b)

11. 12. 13.

15. 16. 17. (a) (b)

AVENSIS REPAIR MANUAL (RM1018E)

MANUAL TRANSAXLE ASSY (1AZFE/1AZFSE)

Air Cleaner Assy

Clip Clip Battery Tray

Engine Cover Subassy No.1

Transmission Control Cable Assy Transverse Engine Engine Mounting Insulator

Backup Lamp Switch Connector

46 (469, 34) 80 (816, 59) 44 (449, 32) 46 (469, 34)

Clutch Release Cylinder Assy

52 (530, 38) 8.4 (85, 74 in.Vlbf)

Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

Manual Transaxle Assy

AVENSIS REPAIR MANUAL (RM1018E)

Front Drive Shaft Assy RH

Front Drive Shaft Assy LH z Snap Ring

Transverse Engine Engine Mounting Bracket

74 (755, 55) 8.0 (82, 71 in.Vlbf)

216 (2,203, 159)

Transverse Engine Engine Mounting Insulator

29 (296, 21) 133 (1,356, 83) 133 (1,356, 83)

Engine Under Cover LH

Engine Under Cover RH

Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

REMOVE STARTER ASSY (See page 1912)

AVENSIS REPAIR MANUAL (RM1018E)

SEPARATE CONNECTOR Separate the backup lamp switch connector.

23. (a) (b)

24. 25. 26. 27. 28.

AVENSIS REPAIR MANUAL (RM1018E)

No.1 Engine Hanger No.2 Engine Hanger

30. 31. (a)