Get MANUAL TRANSAXLE (E351) -> Manual Transaxle Unit Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MX–2

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

COMPONENTS

MX096–03

VSV Connector for EGR

Air Cleaner Case

Assembly

with Air Hose

Air Flow Meter

Connector

No.1 Air Tube Assembly

25 (255, 18)

Clip

ControlCable

Turbo Pressure

Sensor Connector

Clip

Washer

15 (153, 11)

25 (255, 18)

Starter

39 (400, 29)

Battery

Clutch Release

Cylinder

and Line

Stay

Tray

Throttle Full

12 (120, 9)

Switch Connector

52(530,38)

z Gasket

87(890, 64)

12(120,9)

Engine Left

Mounting Bracket

Throttle Control

Motor Connector

21(214,15)

4.9 (50, 43 in.·lbf)

25 (255, 18)

Intake Air Temperature

Sensor Connector

Diesel Throttle Body

with No.2 Air Tube Assembly

: Specified torque

N·m (kgf·cm, ft·lbf)

25 (255, 18)

z Non–reusable part

D06619

AVENSIS/CORONA SUP (RM781E)

MX–3

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

64(650, 47)

Speed Sensor

Connector

RH Drive Shaft

Back–Up Light

Switch Connector

LH Drive

Shaft

z Snap Ring

8.0(82, 71in.·lbf)

Ground Cable

20(204, 15)

46 (470, 34)

216(2,200, 159)

29(300,22)

Lock Nut Cap

64 (650, 47)

z Cotter Pin

98 (1,000, 72)

64 (650, 47)

49 (500, 36)

Tie Rod End

40(408,30)

87(890, 64)

Engine Rear

Mounting Bracket

127 (1,300, 94)

43 (440, 32)

Transaxle Case

Protector

64 (650, 47)

Engine Front

Mounting Bracket

z Gasket

18 (185, 13)

Engine Front

Mounting

Engine Mounting

z Gasket

Front Exhaust Pipe

Center Member

64(650, 47)

40(408,30)

Suction Pipe

Bolt with Spring

73 (740, 54)

52 (540, 38)

62 (630, 46)

Hole Plug

Hole Cover

73 (740, 54)

Hole Plug

Front Transport

Hook

x 10

39 (400, 29)

RH Engine Under Cover

: Specified torque

x 10

N·m (kgf·cm, ft·lbf)

LH Engine Under Cover

z Non–reusable part

D06618

AVENSIS/CORONA SUP (RM781E)

MX–4

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

MX097–03

REMOVAL

1.

2.

REMOVE BATTERY AND TRAY

REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR

HOSE

3.

REMOVE LH AND RH ENGINE UNDER COVERS

4.

REMOVE NO.1 AIR TUBE ASSEMBLY

(a) Disconnect the No.2 vacuum hose from the E–VRV for

EGR.

(b) Disconnect the No.2 vacuum hose from the VSV for EGR.

(c) Disconnect the VSV connector for EGR.

(d) Disconnect the turbo pressure sensor connector and vac-

uum hose.

(b)

(a)

D06626

(e) Remove the 2 bolts as shown in the illustration.

Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)

(f)

Disconnect the 2 hose clips, and remove the No.1 air tube

assembly.

5.

REMOVE DIESEL THROTTLE BODY WITH NO.2 AIR

TUBE ASSEMBLY

(a) Disconnect the intake air temperature sensor connector.

(b) Disconnect the throttle control motor connector.

(c) Disconnect the full opener switch connector.

(d) Remove the 3 bolts from the diesel throttle body.

Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)

D06627

(e) Remove the 2 bolts as shown in the illustration.

Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)

(f)

Disconnect the 2 hose clips, and remove the diesel

throttle body assembly with the No.2 air tube assembly.

D06628

AVENSIS/CORONA SUP (RM781E)

MX–5

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

6.

REMOVE STARTER

(a) Remove the 2 bolts and disconnect the radiator reservoir

from the radiator.

(b) Disconnect the starter connector.

(c) Remove the nut, and disconnect the starter wire.

Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)

(d) Remove the 2 bolts and starter.

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

D06629

D06639

D06633

7.

DISCONNECT CLUTCH RELEASE CYLINDER AND

LINE

(a) Remove the 2 set bolts of the clutch line bracket.

Torque:

Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)

Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)

(b) Remove the 2 bolts and disconnect the release cylinder

and line.

A

B

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

8.

DISCONNECT GROUND CABLE

Remove the set bolt of the ground cable from the transaxle.

9.

DISCONNECT VEHICLE SPEED SENSOR AND

BACK–UP LIGHT SWITCH CONNECTORS

10. DISCONNECT CONTROL CABLE

(a) Remove the 2 clips and washers.

(b) Remove the 2 clips from the cables.

11. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING

A

BOLTS

Torque:

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

Bolt B: 29 N·m (296 kgf·cm, 21 ft·lbf)

A

B

D06636

12. INSTALL ENGINE SUPPORT FIXTURE

Install the engine hanger in the correct direction.

Parts No.:

Engine hanger: 12281–27010

Bolt: 96122–61020

Torque: 37 N·m (377 kgf·cm, 27 ft·lbf)

D06634

AVENSIS/CORONA SUP (RM781E)

MX–6

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

13. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET

BOLTS AND NUT

B

Torque:

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

Nut B: 87 N·m (890 kgf·cm, 64 ft·lbf)

A

D06632

D06638

D08920

14. REMOVE ENGINE LEFT MOUNTING BRACKET

Lower the transaxle side and remove the bolt and bracket.

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

15. REMOVE FRONT WHEEL

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

16. RAISE VEHICLE

NOTICE:

Make sure that the vehicle is securely supported.

17. DRAIN TRANSAXLE OIL

Oil Level

0 – 5 mm

Filler Plug

Oil grade: API GL–4 or GL–5

Viscosity: SAE 75W–90

Capacity: 2.5 liters (2.6 US qts, 2.2 Imp. qts)

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

18. REMOVE FRONT EXHAUST PIPE

(a) Remove the 2 bolts, 2 nuts and gasket from the exhaust

manifold.

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

(b) Remove the 2 bolts, 2 springs, gasket and pipe.

Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)

19. REMOVE LH AND RH FRONT DRIVE SHAFTS

(See page SA–1)

Drain Plug

20. REMOVE ENGINE MOUNTING CENTER MEMBER

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

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

(b) Support the suspension crossmember with a jack.

(c) Remove the nuts, and disconnect the suction pipe.

D06631

AVENSIS/CORONA SUP (RM781E)

MX–7

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

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

(e) Remove the 7 bolts and center member.

Torque:

A

B

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

Bolt B: 52 N·m (540 kgf·cm, 38 ft·lbf)

21. JACK UP TRANSAXLE SLIGHTLY

Using a transmission jack, support the transaxle.

A

D06630

22. REMOVE ENGINE REAR MOUNTING BRACKET

Remove the 4 bolts and bracket.

Torque:

Bolt A: 98 N·m (1,000 kgf·cm, 72 ft·lbf)

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

A

B

D02167

23. REMOVE ENGINE FRONT MOUNT AND MOUNTING

BRACKET

(a) Remove the bolt and nut.

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

(b) Remove the 2 bolts.

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

D06635

24. REMOVE TRANSAXLE LOWER SIDE MOUNTING

BOLT

Remove the 5 bolts.

A

Torque:

Bolt A: 40 N·m (408 kgf·cm, 30 ft·lbf)

Bolt B: 40 N·m (408 kgf·cm, 30 ft·lbf)

Bolt C: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

Bolt D: 20 N·m (204 kgf·cm, 15 ft·lbf)

Bolt E: 46 N·m (470 kgf·cm, 34 ft·lbf)

25. REMOVE TRANSAXLE

Lower engine left side and remove the transaxle from the en-

gine.

B

C

E

D

D06637

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.

26. REMOVE TRANSAXLE CASE PROTECTOR

Remove the 2 bolts and protector.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–8

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

MX05P–03

INSTALLATION

Installation is in the reverse order of removal (See page MX–4).

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 (E351) -> Manual Transaxle Unit for Your Toyota Avensis 4 Door First Generation (1997-2003)

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