4221

CLUTCH CLUTCH ACCUMULATOR ASSY (1CDFTV)

CLUTCH ACCUMULATOR ASSY (1CDFTV)

4202Z03

COMPONENTS
Clutch Line
15 (155, 11) 12 (120, 9)

Wire Harness Clamp

Clutch Accumulator Assy

Clutch Line
12 (120, 9) 15 (155, 11)

Clutch Line
15 (155, 11)

Clutch Release Cylinder

NVm (kgfVcm, ftVlbf) : Specified torque

D30812

AVENSIS REPAIR MANUAL (RM1018E)

4222
CLUTCH CLUTCH ACCUMULATOR ASSY (1CDFTV)
4206G01

REPLACEMENT
1. 2. REMOVE BATTERY REMOVE AIR TUBE NO.1 (See page 14286)

(a)

(b)

3. (a)

REMOVE CLUTCH ACCUMULATOR ASSY Using SST(s), disconnect the flexible hose tube. SST 0902300100

(a) (b) (a) (b)

D30813

HINT: Use a container to catch the fluid. (b) Remove a bolt, 2 nuts and clutch accumulator assy.

(a)

(b)

4. (a)

(a) (b) (a) (b)

D30813

(b)

INSTALL CLUTCH ACCUMULATOR ASSY Using SST(s), connect the 2 flexible hose tubes to the clutch accumulator assy. SST 0902300100 Install the clutch accumulator assy with the 2 nuts and a bolt. Torque: 12 NVm (120 kgfVcm, 9 ftVlbf)

(c)

Using SST(s), tighten the flexible hose tube. SST 0902300100 Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)

SST(s)

D26852

5. 6. 7. (a) 8.

INSTALL AIR TUBE NO.1 (See page 14286) INSTALL BATTERY BLEED CLUTCH PIPE LINE Fill the brake reservoir tank with the brake fluid and bleed clutch system. Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf) CHECK CLUTCH FLUID LEAKAGE

AVENSIS REPAIR MANUAL (RM1018E)

4212
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)

CLUTCH MASTER CYLINDER ASSY (MTM)

4202V03

COMPONENTS
LHD Steering Position Type: Clutch Master Cylinder To Flexible Hose Tube

Clutch Reservoir Tube z Gasket

15 (155, 11)

Clip

12 (120, 9)

Clutch Master Cylinder Push Rod Clevis w/ Hole Pin Clutch Master Cylinder Assy

RHD Steering PositionType: Clutch Master Cylinder To Flexible Hose Tube

Clutch Reservoir Tube

Clutch Master Cylinder Push Rod Clevis w/ Hole Pin z Gasket

15 (155, 11)

12 (120, 9)

Clip Clutch Master Cylinder Assy NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part MP grease

D30477

AVENSIS REPAIR MANUAL (RM1018E)

4213
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
4206E01

REPLACEMENT
1. 2. 3. DRAIN CLUTCH FLUID REMOVE BRAKE MASTER CYLINDER SUBASSY (LHD STEERING POSITION TYPE) (See page 3213) REMOVE BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 3219)

4. (a)

DISCONNECT CLUTCH RESERVOIR TUBE Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder assy.

HINT: Use a container to catch the fluid.

D30068

5. (a)
SST(s)

DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE Using SST(s), disconnect the flexible hose tube. SST 0902300100

HINT: Use a container to catch the fluid.

D30069

RHD Steering Position Type:

6. (a)

REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN Remove the clip and hole pin.

LHD Steering Position Type:

D30782

AVENSIS REPAIR MANUAL (RM1018E)

4214
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)

7. (a) 8. (a)

REMOVE CLUTCH MASTER CYLINDER ASSY Remove the 2 nuts clutch master cylinder assy and gasket. INSTALL CLUTCH MASTER CYLINDER ASSY Install the clutch master cylinder assy and gasket with the 2 nuts. Torque: 12 NVm (120 kgfVcm, 9 ftVlbf) 9. INSTALL CLUTCH MASTER CYLINDER PUSH ROD RHD Steering Position Type: CLEVIS W/HOLE PIN (a) Apply MP grease to the contact surface of the hole pin and clevis bush. (b) Connect the clevis to the clutch pedal assy with the hole pin. HINT: S RHD steering position type: Install the hole pin from the right side of the vehicle. LHD Steering Position Type: S LHD steering position type: Install the hole pin from the left side of the vehicle. (c) Install the clip to the hole pin.

MP Grease

D30782

10. (a)
SST(s)

CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE Using SST(s), connect the flexible hose tube. SST 0902300100 Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)

D30069

11. (a)

CONNECT CLUTCH RESERVOIR TUBE Connect the clutch reservoir tube with the clip to the clutch master cylinder assy. NOTICE: Connect the clutch reservoir tube so as not be twisted.
Blue Mark

D30068

12. 13. 14.

INSTALL BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 3219) INSTALL BRAKE MASTER CYLINDER SUBASSY (LHD STEERING POSITION TYPE) (See page 3213) BLEED BRAKE LINE (LHD STEERING POSITION TYPE) (See page 324)

AVENSIS REPAIR MANUAL (RM1018E)

4215
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)

15. (a) 16. 17. 18. 19. 20.

BLEED CLUTCH PIPE LINE Fill the brake reservoir tank with the clutch fluid and bleed clutch system. Torque: 8.4 NVm (85 kgfVcm, 73 in.Vlbf) CHECK AND ADJUST BRAKE PEDAL HEIGHT (LHD STEERING POSITION TYPE) (See page 326) INSPECT AND ADJUST CLUTCH PEDAL SUBASSY (See page 422) CHECK BRAKE FLUID LEAKAGE (LHD STEERING POSITION TYPE) CHECK CLUTCH FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR

AVENSIS REPAIR MANUAL (RM1018E)

422
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

CLUTCH PEDAL SUBASSY (MTM)

4200D04

ADJUSTMENT
1. (a) INSPECT AND ADJUST CLUTCH PEDAL SUBASSY Turn over the floor carpet.

LHD Steering Position Type: Pedal Height Adjust Point

(b)

Push Rod Play and Free Play Adjust Point

Push Rod Play

(c)

Pedal Height RHD Steering Position Type: Push Rod Play and Free Play Adjust Point Pedal Height Adjust Point

(d)

Check that the pedal height is correct. Pedal height from asphalt sheet: LHD Steering Position Type: 1CDFTV Engine Type 154.0 to 164.0 mm (6.063 to 6.457 in.) Others: 139.6 to 149.6 mm (5.496 to 5.890 in.) RHD Steering Position Type: 1CDFTV Engine Type 158.4 to 168.4 mm (6.236 to 6.630 in.) Others: 148.4 to 158.4 mm (5.843 to 6.236 in.) Adjust the pedal height. (1) Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. Torque: 25 NVm (250 kgfVcm, 18 ftVlbf) Check that the pedal free play and push rod play are correct. (1) Depress the pedal until clutch resistance is felt. Pedal free play: 5.0 to 15.0 mm (0.197 to 0591 in.) (2) Gently depress the pedal until the resistance begins to increase a little. Push rod play at pedal top: 1.0 to 5.0 mm (0.039 to 0.197 in.)

Push Rod Play

Pedal Height
D30053

AVENSIS REPAIR MANUAL (RM1018E)

423
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

(e)

Pedal Free Play

CL0102

Adjust the pedal free play and push rod play. (1) Loosen the lock nut and turn the push rod until the free play and push rod play are correct. (2) Tighten the lock nut. (3) After adjusting the pedal free play, check the pedal height. (4) Connect the air duct and install the lower finish panel.

(f)

25 mm (0.98 in.) or more Release Point

Full Stroke End Position

CL0512

Check the clutch release point. (1) Pull the parking brake lever and install wheel stopper. (2) Start the engine and idle. (3) Without depressing the clutch pedal, slowly adjust the shift lever to the reverse position until the gears contact. (4) Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) If the distance is not as specified, perform the following operations. S Check pedal height. S Check push rod play and pedal free play. S Bleed the clutch line. S Check the clutch cover assy and disc assy.

AVENSIS REPAIR MANUAL (RM1018E)

424
CLUTCH CLUTCH PEDAL SUBASSY (MTM)
4202T02

COMPONENTS
LHD Steering Position Type: w/o Turn Over:
19 (195, 14)

Clip

Clutch Master Cylinder Push Rod Clevis w/ Hole Pin

Clutch Pedal Spring Clutch Pedal No.1 Cushion

37 (375, 27)

Clutch Pedal Bush

12 (120, 9)

Clutch Pedal Support Subassy Clutch Pedal Bush Clutch Pedal Subassy w/ Turn Over: Turn Over Spring Seat Compression Spring

Clutch Master Cylinder Push Rod Clevis Bush

Clutch Pedal Pad Clutch Pedal Turn Over Bush

19 (195, 14)

Clutch Start Switch Assy Clutch Pedal Turn Over Bush Clutch Pedal No.1 Cushion 1CDFTV Engine Type: Clutch Pedal Spring

Clip

Clutch Master Cylinder Push Rod Clevis w/ Hole Pin

37 (375, 27)

Clutch Pedal Support Subassy

16 (160, 12)

12 (120, 9)

z Clutch Pedal Bush Clutch Pedal Subassy

z Clutch Pedal Bush Clutch Master Cylinder Push Rod Clevis Bush

Clutch Pedal Pad NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part MP Grease

D30054

AVENSIS REPAIR MANUAL (RM1018E)

425
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

RHD Power Steering Type: w/o Turn Over: Clutch Master Cylinder Push Rod Clevis w/ Hole Pin
19 (195, 14)

Clutch Pedal Spring Clip

37 (375, 27) 12 (120, 9)

Clutch Pedal Bush Clutch Master Cylinder Push Rod Clevis Bush Clutch Pedal No.1 Cushion

Clutch Pedal Support Subassy

19 (195, 14)

Clutch Pedal Bush Clutch Pedal No.1 Cushion Clutch Pedal Subassy w/ Turn Over: Clutch Master Cylinder Push Rod Clevis w/ Hole Pin Clutch Pedal Turn Over Bush Turn Over Spring Seat Compression Spring
19 (195, 14)

Clutch Pedal Pad Clutch Start Switch Assy

1CDFTV Engine Type: Clutch Pedal Spring Clip

12 (120, 9)

37 (375, 27)

Clutch Pedal Turn Over Bush z Clutch Pedal Bush

16 (160, 12) 19 (195, 14)

Clutch Pedal Support Subassy

z Clutch Pedal Bush Clutch Pedal No.1 Cushion Clutch Pedal Subassy NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part MP Grease
AVENSIS REPAIR MANUAL (RM1018E)

Clutch Master Cylinder Push Rod Clevis Bush Clutch Pedal No.1 Cushion

Clutch Pedal Pad

D30304

426
CLUTCH CLUTCH PEDAL SUBASSY (MTM)
4206D01

REPLACEMENT
1. 2. 3. REMOVE INSTRUMENT PANEL SUBASSY LOWER (LHD STEERING POSITION TYPE) (See page 7111) REMOVE COMBINATION METER ASSY (RHD STEERING POSITION TYPE) (See page 7121) REMOVE CLUTCH PEDAL SPRING

RHD Steering Position Type:

4. (a)

REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN Remove the clip and hole pin.

LHD Steering Position Type:

D30782

LHD Steering Position Type:

RHD Steering Position Type:

5. (a) (b)

REMOVE CLUTCH PEDAL SUPPORT SUBASSY LHD steering position type: Remove the 2 nuts, bolt and clutch pedal support assy. RHD steering position type: Remove the 2 bolts, 2 nuts and clutch pedal support assy.

D26300

AVENSIS REPAIR MANUAL (RM1018E)

427
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

6. (a) (b) 7.

REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING (W/ TURN OVER) Mount the clutch pedal in a soft jaw vise. Using a screwdriver, remove the spring. REMOVE CLUTCH PEDAL TURNOVER BUSH (W/ TURN OVER)

D30775

8. (a)

REMOVE CLUTCH PEDAL TURNOVER BUSH (W/ TURN OVER) Using a 8 mm hexagon wrench and a hammer, remove the turn over bush.

D30776

9. (a) (b)

REMOVE CLUTCH PEDAL SUBASSY Remove the bolt and nut. Remove the clutch pedal from the clutch pedal support.

D30781

10.

REMOVE CLUTCH PEDAL PAD

11. (a)

REMOVE CLUTCH PEDAL BUSH Remove the 2 bushes from the clutch pedal.

D30780

AVENSIS REPAIR MANUAL (RM1018E)

428
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

LHD Steering Position Type:

12. (a)

(b)

REMOVE CLUTCH PEDAL NO.1 CUSHION LHD steering position type: Using needlenose pliers, remove the No.1 cushion from the clutch pedal. RHD steering position type: Using needlenose pliers, remove the 2 No.1 cushions from the clutch pedal.

RHD Steering Position Type:

D30779

13. (a)

REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH Using a 8 mm hexagon wrench and a hammer, remove the clevis bush from the clutch pedal.

D30777

14.

(a) (b) HINT: Install the clevis bush from the right side of the vehicle.

INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH Apply MP grease to the inside of a new clevis bush. Install the clevis bush to the clutch pedal.

MP Grease

D30778

AVENSIS REPAIR MANUAL (RM1018E)

429
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

LHD Steering Position Type:

15. (a)

(b)

INSTALL CLUTCH PEDAL NO.1 CUSHION LHD steering position type: Using needlenose pliers, install the No.1 cushion to the clutch pedal. RHD steering position type: Using needlenose pliers, install the 2 No.1 cushions to the clutch pedal.

RHD Steering Position Type:

D30779

16. (a) (b)

INSTALL CLUTCH PEDAL BUSH Apply MP grease to the inner, outer and end surface of 2 new bushes. Install the 2 bushes to the clutch pedal.

MP Grease

D30780

17.

INSTALL CLUTCH PEDAL PAD

18. (a)

INSTALL CLUTCH PEDAL SUBASSY Install the clutch pedal to the clutch pedal support with the bolt and nut. Torque: 37 NVm (375 kgfVcm, 27 ftVlbf)

HINT: Install the bolt from the right side of the vehicle.

D30781

AVENSIS REPAIR MANUAL (RM1018E)

4210
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

19. (a) (b)

INSTALL CLUTCH PEDAL TURNOVER BUSH (W/ TURN OVER) Apply MP grease to the inside of the turn over bush. Install the turn over bush to the clutch pedal support.

MP Grease

D30783

20. (a) (b) 21. (a)

MP Grease
D30775

(b) 22. (a)

LHD Steering Position Type:

RHD Steering Position Type:

(b)

INSTALL CLUTCH PEDAL TURNOVER BUSH (W/ TURN OVER) Apply MP grease to the inside of the turn over bush. Install the turn over bush to the clutch pedal. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING (W/ TURN OVER) Apply MP grease to the contact surface of the bush and spring. Install the spring to the clutch pedal and clutch pedal support. INSTALL CLUTCH PEDAL SUPPORT SUBASSY LHD steering position type: Install the clutch pedal support to the vehicle with the 2 nuts and bolt. Torque: Bolt: 19 NVm (195 kgfVcm, 14 ftVlbf) Nut: 12 NVm (120 kgfVcm, 9 ftVlbf) RHD steering position type: Install the clutch pedal support to the vehicle with the 2 bolts and 2 nuts. Torque: Bolt: 19 NVm (195 kgfVcm, 14 ftVlbf) Nut: 12 NVm (120 kgfVcm, 9 ftVlbf)

D26300

AVENSIS REPAIR MANUAL (RM1018E)

4211
CLUTCH CLUTCH PEDAL SUBASSY (MTM)

RHD Steering Position Type:

23. (a) (b) HINT:

S S

INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN Apply MP grease to the contact surface of the hole pin and clevis bush. Connect the clevis to the clutch pedal with the hole pin. RHD steering position type: Install the hole pin from the right side of the vehicle. LHD steering position type: Install the hole pin from the left side of the vehicle. Install the clip to the hole pin.

LHD Steering Position Type:

(c)

MP Grease

D30782

24. 25. 26. 27.

INSTALL CLUTCH PEDAL SPRING INSTALL COMBINATION METER ASSY (RHD STEERING POSITION TYPE) (See page 7121) INSTALL INSTRUMENT PANEL SUBASSY LOWER (LHD STEERING POSITION TYPE) (See page 7111) INSPECT AND ADJUST CLUTCH PEDAL SUBASSY (See page 422)

AVENSIS REPAIR MANUAL (RM1018E)

4216
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)

CLUTCH RELEASE CYLINDER ASSY (MTM)

4202X03

COMPONENTS
1CDFTV Engine Type:
12 (120, 9)

Clutch Accumulator Assy

12 (120, 9)

Wire Harness Clamp

15 (155, 11) 12 (120, 9) 15 (155, 11)

Release Cylinder Body

1AZFSE/1AZFE Engine Type:

12 (120, 9)

Release Cylinder Body

12 (122, 9)

Clutch Line Clamp

15 (155, 11)

1ZZFE/3ZZFE Engine Type:

5.0 (51, 44 in.Vlbf)

15 (155, 11)

Clutch Line Clamp Clutch Line Bracket

14 (141, 10)

Release Cylinder Body Piston Bleeder Plug Cap Boot NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part Push Rod Lithium soap glycol grease Bleeder Plug
8.4 (85, 74 in.Vlbf)
D30055

z Spring

AVENSIS REPAIR MANUAL (RM1018E)

4217
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)
4206F01

OVERHAUL
1. 2. REMOVE BATTERY (1CDFTV ENGINE TYPE) REMOVE AIR TUBE NO.1 (1CDFTV ENGINE TYPE) (See page 14286)

1ZZFE/3ZZFE Engine Type:

3.

SST(s)

(a)

DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (EXCEPT 1CDFTV ENGINE TYPE) Using SST(s), disconnect the flexible hose tube. SST 0902300100

HINT: Use a container to catch the fluid.

1AZFE/1AZFSE Engine Type:

SST(s)
D30487

4. (a) (b)

REMOVE CLUTCH ACCUMULATOR ASSY (1CDFTV ENGINE TYPE) Disconnect the wire harness clamp. Using SST(s), disconnect the 2 flexible hose tubes. SST 0902300100

HINT: Use a container to catch the fluid. (c) Remove the 2 nuts, bolt and clutch accumulator assy.
D30814

AVENSIS REPAIR MANUAL (RM1018E)

4218
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)

1ZZFE/3ZZFE Engine Type:

5. (a)

(b)

REMOVE CLUTCH RELEASE CYLINDER ASSY (EXCEPT 1CDFTV ENGINE TYPE) 1ZZFE/3ZZFE Engine Type: Remove the 3 bolts, clutch release cylinder assy, and clutch line bracket. 1AZFE/1AZFSE Engine Type: Remove the 3 bolts and clutch release cylinder assy.

1AZFE/1AZFSE Engine Type:

D30488

6. (a)

REMOVE CLUTCH RELEASE CYLINDER ASSY (1CDFTV ENGINE TYPE) Using a 12 mm deep socket wrench, remove the 2 bolts and clutch release cylinder assy.

D26804

7. REMOVE CLUTCH RELEASE CYLINDER KIT (a) Remove the boot from the cylinder body. (b) Remove the push rod from the cylinder body. (c) Remove the piston from the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (d) Remove the spring from the cylinder body. (e) Remove the bleeder plug cap from the bleeder plug. 8. REMOVE RELEASE CYLINDER BLEEDER PLUG 9. INSTALL RELEASE CYLINDER BLEEDER PLUG Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)

AVENSIS REPAIR MANUAL (RM1018E)

4219
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)

10. (a) (b)

INSTALL CLUTCH RELEASE CYLINDER KIT Install the bleeder plug cap to the bleeder plug. Install a new spring to the cylinder body.

(c)

Coat the parts with lithium soap base glycol grease, as shown in the illustration. (d) Install the piston to the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (e) Install the push rod to the cylinder body. (f) Install the boot to the cylinder body.
CL0672

11. (a)

INSTALL CLUTCH RELEASE CYLINDER ASSY (1CDFTV ENGINE TYPE) Using a 12 mm deep socket wrench, install the clutch release cylinder assy with the 2 bolts. Torque: 12 NVm (120 kgfVcm, 9 ftVlbf)

D26804

1ZZFE/3ZZFE Engine Type: (2) (1) (1)

12. (a)

(b)
1AZFE/1AZFSE Engine Type: (1) (1)

INSTALL CLUTCH RELEASE CYLINDER ASSY (EXCEPT 1CDFTV ENGINE TYPE) 1ZZFE/3ZZFE Engine Type: (1) Install the clutch release cylinder and clutch line bracket with the 2 bolts. Torque: 14 NVm (141 kgfVcm, 10 ftVlbf) (2) Install the flexible hose tube with the bolt. Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) 1AZFE/1AZFSE Engine Type: (1) Install the clutch release cylinder with the 2 bolts. Torque: 12 NVm (120 kgfVcm, 9 ftVlbf) (2) Install the flexible hose tube with the bolt. Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)

(2)
D30488

AVENSIS REPAIR MANUAL (RM1018E)

4220
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)

13. (a)

(b)

D30814

(c) 14.

INSTALL CLUTCH ACCUMULATOR ASSY (1CDFTV ENGINE TYPE) Install the clutch accumulator assy with the 2 nuts and bolt. Torque: 12 NVm (120 kgfVcm, 9 ftVlbf) Using SST(s), connect the 2 flexible hose tubes. SST 0902300100 Torque: 15 NVm (155 kgfVcm, 11 ftVlbf) Connect the wire harness clamp. CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (EXCEPT 1CDFTV ENGINE TYPE) Using SST(s), connect the flexible hose tube. SST 0902300100 Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)

1ZZFE/3ZZFE Engine Type:

SST(s)

(a)

1AZFE/1AZFSE Engine Type:

SST(s)
D30487

15. 16. 17. (a) 18.

INSTALL AIR TUBE NO.1 (1CDFTV ENGINE TYPE) (See page 14286) INSTALL BATTERY (1CDFTV ENGINE TYPE) BLEED CLUTCH PIPE LINE Fill the brake reservoir tank with the brake fluid and bleed clutch system. Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf) CHECK CLUTCH FLUID LEAKAGE

AVENSIS REPAIR MANUAL (RM1018E)

421
CLUTCH CLUTCH SYSTEM (MTM)

CLUTCH SYSTEM (MTM)

4200B04

PROBLEM SYMPTOMS TABLE

HINT: 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.
Symptom 1. 2. 3. 4. 5. 6. 7. Suspect Area Engine mounting (Loosen) Clutch disc assy (Runout is excessive) Clutch disc assy (Oily) Clutch disc assy (Worn out) Clutch disc torsion rubber (Damaged) Clutch disc assy (Glazed) Diaphragm spring (Out of tip alignment) See page 4226 4226 4226 4226 4226 4226 4213 4217 4226 4226 422 4226 4226 4226 4226 422 4213 4217 4226 4226 4226 4226 4226 4226

Clutch grabs/chatters

Clutch pedal spongy

1. Clutch Line (Air in line) 2. Master cylinder (Damaged) 3. Release cylinder rubber (Damaged) 1. Clutch release bearing assy (Worn, dirty, or damaged) 2. Clutch disc torsion rubber (Damaged) 1. 2. 3. 4. 5. 6. Clutch pedal (Free play out of adjustment) Clutch disc assy (Oily) Clutch disc assy (Worn out) Diaphragm spring (Damaged) Pressure plate (Distortion) Flywheel subassy (Distortion)

Clutch noisy

Clutch slips

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)

AVENSIS REPAIR MANUAL (RM1018E)

4223
CLUTCH CLUTCH UNIT (MTM)

CLUTCH UNIT (MTM)

4206H01

COMPONENTS
1ZZFE/3ZZFE Engine Type:

Clutch Disc Assy

19 (194, 14)

Clutch Release x6 Fork Subassy Clutch Release Bearing Assy Release Bearing Hub Clip

Flywheel Subassy

Clutch Cover Assy Release Fork Support

37 (375, 27)

Clutch Release Fork Boot NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part Clutch spline grease Release hub grease

D26321

AVENSIS REPAIR MANUAL (RM1018E)

4224
CLUTCH CLUTCH UNIT (MTM)

1AZFSE/1AZFE Engine Type:

Flywheel Subassy

19 (194, 14)

x6

Clutch Release Bearing Assy Release Bearing Hub Clip

Clutch Disc Assy

Release Fork Support

48 (480, 35)

Clutch Cover Assy Clutch Release Fork Subassy Clutch Release Fork Boot

NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part Clutch spline grease Release hub grease
D30056

AVENSIS REPAIR MANUAL (RM1018E)

4225
CLUTCH CLUTCH UNIT (MTM)

1CDFTV Engine Type:

Clutch Cover Assy Clutch Disc Assy Clutch Release Bearing Assy

Release Bearing Hub Clip

Flywheel Subassy

x6
19 (194, 14)

Clutch Release Fork Subassy Release Fork Support

37 (375, 27)

NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part Clutch spline grease Release hub grease

Clutch Release Fork Boot

D30057

AVENSIS REPAIR MANUAL (RM1018E)

4226
CLUTCH CLUTCH UNIT (MTM)
4200G05

OVERHAUL
1. (a) (b) (c) REMOVE MANUAL TRANSAXLE ASSY 1ZZFE, 3ZZFE Engine (See page 4115) 1AZFE, 1AZFSE Engine (See page 4124) 1CDFTV Engine (See page 4133)

EXCEPT 1CDFTV Engine Type:

2. (a)

REMOVE CLUTCH RELEASE FORK SUBASSY Remove the clutch release fork with clutch release bearing from the transaxle assy.

1CDFTV Engine Type:

D26951

3. (a) 4. (a) 5. 6.

REMOVE CLUTCH RELEASE BEARING ASSY Remove the clutch release bearing assy from the clutch release fork. REMOVE RELEASE FORK SUPPORT Remove the release fork support from the transaxle assy. REMOVE RELEASE BEARING HUB CLIP REMOVE CLUTCH RELEASE FORK BOOT

7. (a)

C62955

REMOVE CLUTCH COVER ASSY Align matchmarks on the clutch cover assy with the one on the flywheel subassy. (b) Loosen each set bolt one turn at a time until the spring tension is released. (c) Remove the set bolts, and pull off the clutch cover assy. NOTICE: Do not drop the clutch disc assy.
Matchmarks
D25280

AVENSIS REPAIR MANUAL (RM1018E)

4227
CLUTCH CLUTCH UNIT (MTM)

8. REMOVE CLUTCH DISC ASSY NOTICE: Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel subassy away from oil and foreign attachment. INSPECT CLUTCH DISC ASSY Using vernier calipers, measure the rivet head depth. Maximum rivet depth: 0.3 mm (0.012 in.) Replace the clutch disc assy as necessary. (b) Install the clutch disc assy to the transaxle assy. NOTICE: Take care not to insert the clutch disc assy in the wrong direction. (c) Using a dial gage, check the clutch disc assy runout. Minimum runout: 0.8 mm (0.031 in.) Replace the clutch disc assy as necessary. 9. (a)

C62956

1CDFTV Engine Type:

Others: Transaxle Side

D30058

10. (a)

INSPECT CLUTCH COVER ASSY Using vernier calipers, inspect the diaphragm spring for the depth and width of wear. Maximum: A (Depth): 0.5 mm (0.020 in.) B (Width): 6.0 mm (0.236 in.) Replace the clutch cover assy as necessary.
D25281

C57466

11. (a)

INSPECT FLYWHEEL SUBASSY Using a dial gage, inspect the flywheel subassy runout. Maximum runout: 0.1 mm (0.004 in.) Replace the flywheel subassy as necessary.

C62958

AVENSIS REPAIR MANUAL (RM1018E)

4228
CLUTCH CLUTCH UNIT (MTM)

12. (a)

INSPECT CLUTCH RELEASE BEARING ASSY Turn the release bearing by hand while applying force in the axial direction.

Q01060

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 subassy. SST 0930100220 NOTICE: Take care not to insert the clutch disc assy in the wrong direction.
Others:

1CDFTV Engine Type:

Flywheel Side

SST(s)
D30059

SST(s) 3 6

1 (Temporally), 4

14. (a) (b)

8 2.5 Matchmarks
D26323

INSTALL CLUTCH COVER ASSY Align matchmarks on the clutch cover assy and flywheel subassy. 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 NVm (195 kgfVcm, 14 ftVlbf) 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.

HINT:
S S

SST(s)

15. (a)

INSPECT AND ADJUST CLUTCH COVER ASSY Using a dial indicator with roller instrument, check the diaphragm spring tip alignment. Maximum nonalignment: 0.5 mm (0.020 in.) If the alignment is not as specified, adjust the diaphragm spring tip alignment using SST(s). SST 0933300013
D00205

AVENSIS REPAIR MANUAL (RM1018E)

4229
CLUTCH CLUTCH UNIT (MTM)

16. (a)

17.

INSTALL RELEASE FORK SUPPORT Install the release fork support to the transaxle assy. Torque: 1ZZFE/3ZZFE/1CDFTV Engine Type: 37 NVm (375 kgfVcm, 27 ftVlbf) 1AZFSE/1AZFE Engine Type: 47 NVm (480 kgfVcm, 35 ftVlbf) INSTALL RELEASE BEARING HUB CLIP

EXCEPT 1CDFTV Engine Type:

18. (a)

(b)
1CDFTV Engine Type:

INSTALL CLUTCH RELEASE FORK SUBASSY Apply the release hub grease to the release fork and release bearing assy contact, release fork and push rod contact, and release fork pivot points. Sealant: Part No. 0888701806, RELEASE HUB GREASE or equivalent Install the release fork to the release bearing assy.

Release Hub Grease

D26819

19. (a)

INSTALL CLUTCH RELEASE BEARING ASSY Apply the clutch spline grease to the input shaft spline. Sealant: Part No. 0888701706, CLUTCH SPLINE GREASE or equivalent (b) Install the bearing to the release fork, and then install them to the transaxle 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) 1ZZFE, 3ZZFE Engine (See page 4115) (b) 1AZFE, 1AZFSE Engine (See page 4124) (c) 1CDFTV Engine (See page 4133)

AVENSIS REPAIR MANUAL (RM1018E)