Get MANUAL TRANSAXLE (C50, C250) -> Manual Transaxle Unit Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MX–2

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

MX06E–02

COMPONENTS

RH Drive Shaft

Battery

Tray

z Snap Ring

Back–Up Light SwitchConnector

Speed Sensor Connector

Engine Wire

87(890, 64)

46 (470, 34)

39(400, 29)

Air Cleaner

Case Assembly

with Air Hose

Starter

64 (650, 47)

39 (400, 29)

Ground Cable

Clip

43 (440, 32)

Washer

Control Cable

Transaxle

Snap Ring

z

LH Drive Shaft

4A–FE Engine:

43 (440, 32)

216 (2,200, 159)

52 (530, 38)

Lock NutCap

64 (650, 47)

87(890, 64)

z

Cotter Pin

12 (120, 9)

49 (500, 36)

Stiffener Plate

127(1,300, 94)

Tie Rod End

Engine Mounting

Center Member

12 (120, 9)

43 (430, 32)

z

^zGasket

Clutch Release Cylinder

z

62 (630, 46)

Engine Left

Mounting Bracket

73 (740, 54)

Front and Center

Exhaust Pipes

Hole Plug

72 (730, 53)

Hole Cover

Hole Plug

Front TransportHook

LH Engine Under Cover

RH Engine Under Cover

N·m (kgf·cm, ft·lbf)

73 (740, 54)

39 (400, 29)

: Specifiedtorque

zNon–reusable part

D09353

AVENSIS/CORONA SUP (RM781E)

MX–3

MANUALTRANSAXLE (C50, C250)

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MANUALTRANSAXLE UNIT

MX0CZ–01

REMOVAL

1.

REMOVE BATTERY AND AIR CLEANER CASE AS-

SEMBLY WITH AIR HOSE

2.

DISCONNECT CLUTCH RELEASE CYLINDER AND

LINE

(a) Remove the set bolt of the clutch line bracket.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

(b) Remove the 2 bolts and disconnect the clutch release cyl-

inder and line.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D02142

D02143

D02144

3.

DISCONNECT ENGINE WIRE FROM CLAMP

Remove the bolt and engine wire clamp from the transaxle.

4.

DISCONNECT BACK–UP LIGHT SWITCH AND SPEED

SENSOR CONNECTORS

5.

DISCONNECT GROUND CABLE

Remove the set bolt and disconnect the ground cable from the

transaxle.

6.

(a) Remove the 2 clips and washers.

(b) Remove the 2 clips from the cables.

(c) Disconnect the 2 control cables from the transaxle.

DISCONNECT CONTROL CABLE

7.

REMOVE STARTER SET BOLT

Remove the set bolt of the starter from the transaxle upper side.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

8.

REMOVE 3 TRANSAXLE UPPER SIDE MOUNTING

BOLTS

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

Starter Set Bolt

D02145

AVENSIS/CORONA SUP (RM781E)

MX–4

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

9.

INSTALL ENGINE SUPPORT FIXTURE

D02147

10. REMOVE ENGINE LEFT MOUNTING BRACKET

Remove the 4 bolts, nut and bracket.

Torque:

B

Bolt A: 52 N·m (530 kgf·cm, 38 ft·lbf)

Nut B : 87 N·m (890 kgf·cm, 64 ft·lbf)

11. REMOVE FRONT WHEEL

A

Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)

12. RAISE VEHICLE

NOTICE:

D02146

Make sure that the vehicle is securely supported.

13. REMOVE LH AND RH ENGINE UNDER COVERS

14. DRAIN TRANSAXLE OIL

Oil grade: API GL–4 or GL–5

Viscosity: SAE 75W–90

Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

15. REMOVE LH AND RH DRIVE SHAFTS

(See page SA–1)

Filler Plug

Oil Level

0 – 5 mm

Drain Plug

D08837

16. REMOVE FRONT AND CENTER EXHAUST PIPES

(a) Remove the 3 nuts and 2 gaskets from the exhaust man-

ifold.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)

(b) Remove the 2 bolts, nuts, gasket and front and center ex-

haust pipes.

Torque: 43 N·m (430 kgf·cm, 32 ft·lbf)

D02149

AVENSIS/CORONA SUP (RM781E)

MX–5

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

17. REMOVE ENGINE MOUNTING CENTER MEMBER

(a) Remove the 2 bolts and front transport hook.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

D02150

(b) Remove the 2 hole plugs and hole cover.

(c) Remove the 7 bolts and center member.

Torque:

A

B

A

Bolt A: 73 N·m (740 kgf·cm, 54 ft·lbf)

Bolt B: 72 N·m (730 kgf·cm, 53 ft·lbf)

D02151

D02152

D02153

D00193

18. REMOVE STARTER

(a) Disconnect the connector and wire from the starter.

(b) Remove the set bolt of the starter from the lower side.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

(c) Remove the starter.

19. JACK UP TRANSAXLE SLIGHTLY

Using a transmission jack, support the transaxle.

20. REMOVE ENGINE REAR MOUNTING BOLT

Torque: 87 N·m (890 kgf·cm, 64 ft·lbf)

21. REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING

BOLT

Remove the 4 bolts.

A

Torque:

Bolt A: 47 N·m (480 kgf·cm, 35 ft·lbf)

Bolt B: 23 N·m (230 kgf·cm, 17 ft·lbf)

B

AVENSIS/CORONA SUP (RM781E)

MX–6

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

22. REMOVE TRANSAXLE

Lower the engine left side and remove the transaxle from the

engine.

HINT:

At the time of installation, please refer to the following items.

S

Align the input shaft with the clutch disc and install the

transaxle to the engine.

S

Temporarily tighten the transaxle mounting bolts.

AVENSIS/CORONA SUP (RM781E)

MX–7

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

MX005–04

INSTALLATION

Installation is in the reverse order of removal (See page MX–3).

HINT:

After installation, check and inspect items as follows.

S

Front wheel alignment (See Pub. No. RM599E on page SA–4).

Do the road test.

S

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (C50, C250) -> Manual Transaxle Unit for Your Toyota Avensis 4 Door First Generation (1997-2003)

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