FLOOR SHIFT SHIFT LEVER ASSY (MTM) - …docshare01.docshare.tips/files/10714/107141512.pdf · d26972 d26894 serrate part 41–12 manual transmission/transaxle – floor shift shift

4105U–03

D30489

Gasoline Engine:Front FloorHeat Insulator No.1

Console Box Carpet

Floor Shift Lever KnobSub–assy

Console Panel Sub–assy Upper

Console Panel Sub–assy Lower

Console Box Sub–assy Rear

Clip

Clip

Clip

5.0 (51, 44 in. �lbf)

5.0 (51, 44 in. �lbf)

Clip Clip

12 (122, 9)

Floor Shift Shift Lever Assy

12 (122, 9)

N·m (kgf·cm, ft·lbf) : Specified torque

5.5 (56, 49 in. �lbf)

Transmission Control Cable Assy

41–10–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)

AVENSIS REPAIR MANUAL (RM1018E)

FLOOR SHIFT SHIFT LEVER ASSY (MTM)COMPONENTS

410DR–01

D26893

D26895

D30474

D30474

–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)41–11


REPLACEMENT1. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB–ASSY (See page 71–11)2. REMOVE CONSOLE PANEL UPPER (See page 71–11)3. REMOVE CONSOLE PANEL SUB–ASSY LOWER (See page 71–11)4. REMOVE CONSOLE BOX ASSY REAR (See page 71–11)

5. SEPARATE TRANSMISSION CONTROL CABLE ASSY(a) Remove the 2 clips, separate the cable ends of the control

cable assy.

(b) Release the claws, separate the control cable assy.

6. REMOVE FLOOR SHIFT SHIFT LEVER ASSY(a) Remove the 4 bolts and shift lever assy.

7. INSTALL FLOOR SHIFT SHIFT LEVER ASSY(a) Install the shift lever assy with the 4 bolts.

Torque: 12 N �m (122 kgf �cm, 9 ft �lbf)

D26972

D26894

Serrate Part

41–12–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)


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.

(b) Connect the end of the select cable to the shift lever assy,install the clip.

NOTICE:� The serrate part of the select cable point should face

upward when the select cable point is connected.� 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.

41046–11

C94266

SST(s)

D25305

SST(s)

D25722

SST(s)

–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)41–3


FRONT DIFFERENTIAL OIL SEAL (C50/C250)REPLACEMENT1. DRAIN MANUAL TRANSAXLE OIL

Torque: 39 N �m (400 kgf �cm, 29 ft �lbf)2. REMOVE FRONT WHEELS3. REMOVE ENGINE UNDER COVER LH4. REMOVE ENGINE UNDER COVER RH5. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)

SST 09520–01010, 09520–24010 (09520–32040)6. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6)

SST 09520–01010, 09520–24010 (09520–32040)

7. REMOVE TRANSAXLE CASE OIL SEAL(a) Using SST(s), remove the oil seal.

SST 09308–00010

8. REMOVE TRANSMISSION CASE OIL SEAL(a) Using SST(s), remove the oil seal.

SST 09308–00010

9. INSTALL TRANSAXLE 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: 1.9 � 0.3 mm (0.075 � 0.012 in.)

NOTICE:Be careful not to damage the oil seal lip.

D26133

SST(s)

D25304

0 to 5 mm (0 to 0.20 in.)

41–4–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)


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.



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 OILOil grade: API GL–4 or GL–5Viscosity: SAE 75 W–90Capacity: 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)

41046–12

C94266

SST(s)

D25305

SST(s)

D25722

SST(s)

–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)41–5


FRONT DIFFERENTIAL OIL SEAL (E354/E357)REPLACEMENT1. DRAIN MANUAL TRANSAXLE OIL

Torque: 49 N �m (500 kgf �cm, 36 ft �lbf)2. REMOVE FRONT WHEELS3. REMOVE ENGINE UNDER COVER LH4. REMOVE ENGINE UNDER COVER RH5. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)

SST 09520–01010, 09520–24010 (09520–32040)6. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6)

SST 09520–01010, 09520–24010 (09520–32040)

7. REMOVE FRONT TRANSAXLE CASE COVER OILSEAL

(a) Using SST(s), remove the oil seal.SST 09308–00010

8. REMOVE TRANSMISSION CASE OIL SEAL(a) Using SST(s), remove the oil seal.

SST 09308–00010

9. INSTALL FRONT TRANSAXLE CASE COVER OILSEAL

(a) Coat a new oil seal lip with MP grease.(b) Using SST(s) and a hammer, install the oil seal.

SST 09608–10010, 09950–70010 (09951–07200)Drive in depth: 0 � 0.5 mm (0 � 0.020 in.)


D26133

SST(s)

D25304

0 to 5 mm (0 to 0.20 in.)

41–6–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)


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.



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 OILOil grade: API GL–4 or GL–5Viscosity: SAE 75 W–90Capacity: 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)

410DT–01

D30082

13 (133, 10)Hood Sub–assy

Engine Cover Sub–assy No.1

Air Cleaner Assy

Battery

Battery Tray

Clip

Clip

Clip

Starter Assy

64 (653, 47)

80 (816, 59)

52 (530, 38)18 (184, 13)

� Non–reusable partN·m (kgf·cm, ft·lbf) : Specified torque

12 (120, 9)

Manual Transaxle Assy

46 (469, 34)

Transverse Engine Engine Mounting Insulator

9.0 (92, 80 in. �lbf)

Engine Room Cover Side

Radiator Support Opening Cover

44 (449, 32)

44 (449, 32)

Clutch Release Cylinder Assy

Starter Connector

37 (380, 27)

13 (130, 9)

46 (469, 34)

8.4 (85, 74 in. �lbf)

46 (469, 34)


Battery Clamp Sub–assy

5.0 (51, 44 in. �lbf)

9.0 (92, 80 in. �lbf)

Back–up Lamp Switch Connector

5.0 (51, 44 in. �lbf)

Clip

26 (260, 19)

40 (410, 30)

64 (653, 47)

52 (530, 38)

13 (131, 9)

41–22–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)


MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)COMPONENTS

D30473

Front Drive Shaft Assy RH

� Snap Ring

Transverse EngineEngine Mounting Insulator

64 (653, 47)

87 (887, 64)

� Cotter Pin64 (653, 47)

� Cotter Pin

Engine Under Cover RH

� Non–reusable part


64 (653, 47)

� 216 (2,203, 159)45 (459, 33)

Engine Under Cover LH

35 (360, 26)

74 (755, 55)

52 (530, 38)

49 (500, 36)

133 (1,356, 83)

49 (500, 36)

89 (908, 66)

Transverse EngineEngine Mounting Bracket

133 (1,356, 83)

52 (530, 38) 89 (908, 66)

29 (296, 21)Transverse EngineEngine Mounting Insulator


8.0 (82, 71 in. �lbf)

74 (755, 55)

Front Drive Shaft Assy LH

64 (650, 47)

64 (650, 47)

–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ–FE/1AZ–FSE)41–23


410DU–01

D30480

D30081



REPLACEMENT1. INSPECT CENTER FRONT WHEEL2. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50–9)3. SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50–9)4. REMOVE STEERING COLUMN HOLE COVER SUB–ASSY NO.1 (See page 50–9)5. REMOVE STEERING INTERMEDIATE SHAFT (See page 50–9)6. REMOVE FRONT WHEELS7. REMOVE ENGINE UNDER COVER LH8. REMOVE ENGINE UNDER COVER RH9. DRAIN TRANSAXLE OIL

Torque: 49 N �m (500 kgf �cm, 36 ft �lbf)10. REMOVE HOOD SUB–ASSY11. REMOVE RADIATOR SUPPORT OPENING COVER12. REMOVE ENGINE ROOM COVER SIDE13. REMOVE ENGINE COVER SUB–ASSY NO.114. REMOVE AIR CLEANER ASSY15. REMOVE BATTERY CLAMP SUB–ASSY16. REMOVE BATTERY17. REMOVE BATTERY TRAY

18. REMOVE BATTERY CARRIER(a) Remove the 4 bolts and battery carrier.

19. REMOVE STARTER ASSY (See page 19–12)

20. SEPARATE WIRE HARNESS(a) Remove the 3 bolts, and separate the 3 wire harnesses.

D30066

D30064

G24413



21. SEPARATE CONNECTOR(a) Separate the back–up lamp switch connector.

22. SEPARATE CLUTCH RELEASE CYLINDER ASSY(a) Remove the 3 bolts and separate the release cylinder.

23. SEPARATE TRANSMISSION CONTROL CABLE ASSY(a) Remove the 2 clips, separate the 2 cables from the trans-

axle.(b) Remove the 2 clips, separate the 2 cables from the brack-

et.

24. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)SST 09520–01010, 09520–24010 (09520–32040)

25. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6)26. REMOVE HEIGHT CONTROL SENSOR SUB–ASSY FR RH (W/ DISCHARGE HEAD LAMP)

(See page 65–28)27. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51–36)

SST 09023–1270028. DISCONNECT PRESSURE FEED TUBE ASSY (See page 51–36)

SST 09023–12700

D25745

No.1 Engine Hanger No.2 Engine Hanger

D30067

D30077

D25747



29. SUSPEND ENGINE ASSY(a) Install the No.1 and No.2 engine hangers in the correct

direction.Parts No.:No. 1 engine hanger: 12281–28010No. 2 engine hanger: 12282–28010Bolt: 91512–61020Torque: 38 N �m (387 kgf �cm, 28 ft �lbf)

(b) Attach the engine chain hoist to the engine hanger.CAUTION:Do not attempt to hang the engine by hooking the chain toany other part.

30. REMOVE FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–26)31. SUPPORT MANUAL TRANSAXLE ASSY(a) Support the manual transaxle with a transmission jack.

32. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR

(a) Remove the 5 bolts, nut and engine mounting insulatorLH.

33. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET

(a) Remove the 3 bolts and engine mounting bracket.

34. REMOVE MANUAL TRANSAXLE ASSY(a) Separate the wire harness clamp.(b) Remove the 10 bolts.(c) Separate and remove the transaxle from the engine.

D30076

D30078

D30079

D30079

(a)

(a)

(a)(b)

D30078

(a)

(b)

(b)

(a)



35. REMOVE MANUAL TRANSMISSION CASEPROTECTOR

(a) Remove the 2 bolts and case protector.


(a) Remove the bolt, nut and engine mounting insulator FRfrom the engine mounting bracket.

(b) Remove the 2 bolts and engine mounting bracket FR fromthe transaxle.


(a) Remove the bolt and engine mounting insulator RR fromthe engine mounting bracket.

(b) Remove the 3 bolts and engine mounting bracket RRfrom the transaxle.

38. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGBRACKET

(a) Install the engine mounting bracket RR and 3 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)

(b) Install the engine mounting insulator RR and bolt to theengine mounting bracket RR.Torque: 87 N �m (887 kgf �cm, 64 ft �lbf)


(a) Install the engine mounting bracket FR and 2 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)

(b) Install the engine mounting insulator FR, bolt and nut tothe engine mounting bracket FR.Torque: 52 N �m (530 kgf �cm, 38 ft �lbf)

D30076

D25747

AB

CB

A

D30077

D30067

A

A

A

A

B



40. INSTALL MANUAL TRANSMISSION CASEPROTECTOR

(a) Install the case protector with the 2 bolts.Torque: 18 N �m (184 kgf �cm, 13 ft �lbf)

41. INSTALL MANUAL TRANSAXLE ASSY(a) Align the input shaft with the clutch disc and install the

transaxle to the engine.(b) Install the 10 bolts.

Torque:Bolt A: 64 N �m (653 kgf �cm, 47 ft �lbf)Bolt B: 46 N �m (469 kgf �cm, 34 ft �lbf)Bolt C: 44 N �m (449 kgf �cm, 32 ft �lbf)

(c) Connect the wire harness clamp.


(a) Install the engine mounting bracket LH to the transaxlewith the 3 bolt.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)

43. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGINSULATOR

(a) Install the engine mounting insulator LH with the 5 boltsand nut.Torque:Bolt A: 52 N �m (530 kgf �cm, 38 ft �lbf)Bolt B: 80 N �m (816 kgf �cm, 59 ft �lbf)

44. INSTALL FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–26)SST 09670–00010

45. CONNECT PRESSURE FEED TUBE ASSY (See page 51–36)SST 09023–12700

46. CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51–36)SST 09023–12700

47. INSTALL HEIGHT CONTROL SENSOR SUB–ASSY FR RH (W/ DISCHARGE HEAD LAMP)(See page 65–28)

48. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–6)49. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–6)

G24413

D30064

A

B

D30066

D30081

B

C

A



50. INSTALL TRANSMISSION CONTROL CABLE ASSY(a) Connect the 2 cable ends, install the 2 clips.(b) Install the 2 clips to the control cable bracket.

51. INSTALL CLUTCH RELEASE CYLINDER ASSY(a) Install the release cylinder with the 3 bolts.

Torque:Bolt A: 9.0 N �m (92 kgf �cm, 80 in. �lbf)Bolt B: 12 N �m (120 kgf �cm, 9 ft �lbf)

52. CONNECT CONNECTOR(a) Connect the back–up lamp switch connector.

53. CONNECT WIRE HARNESS(a) Install the 3 wire harnesses with the 3 bolts.

Torque: Bolt A: 26 N �m (260 kgf �cm, 19 ft �lbf)Bolt B: 8.4 N �m (85 kgf �cm, 74 in. �lbf)Bolt C: 40 N �m (410 kgf �cm, 30 ft �lbf)

54. INSTALL STARTER ASSY (See page 19–12)

D30080



55. INSTALL BATTERY CARRIER(a) Install the battery carrier and 4 bolts.


56. INSTALL BATTERY TRAY57. INSTALL BATTERY58. INSTALL BATTERY CLAMP SUB–ASSY

Torque: Bolt: 5.0 N �m (51 kgf �cm, 44 in. �lbf)Nut: 3.5 N �m (36 kgf �cm, 31 in. �lbf)

59. INSTALL AIR CLEANER ASSYTorque: 5.0 N �m (51 kgf �cm, 44 in. �lbf)

60. INSTALL ENGINE COVER SUB–ASSY NO.1Torque: 9.0 N �m (92 kgf �cm, 80 in. �lbf)

61. INSTALL ENGINE ROOM COVER SIDE62. INSTALL RADIATOR SUPPORT OPENING COVER63. INSTALL HOOD SUB–ASSY

Torque: 13 N �m (132 kgf �cm, 10 ft �lbf)64. INSPECT HOOD SUB–ASSY (See page 75–2)65. ADJUST HOOD SUB–ASSY (See page 75–2)66. ADD TRANSAXLE OIL (See page 41–5)67. INSPECT TRANSAXLE OIL (See page 41–2)68. INSTALL FRONT WHEELS

Torque: 103 N �m (1,050 kgf �cm, 76 ft �lbf)69. INSTALL STEERING INTERMEDIATE SHAFT (See page 50–9)70. INSTALL STEERING COLUMN HOLE COVER SUB–ASSY NO.1 (See page)See page 50–9)71. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50–9)72. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50–9)73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD74. STEERING WHEEL CENTER POINT75. ADD POWER STEERING FLUID76. BLEED POWER STEERING FLUID (See page 51–4)77. CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51–4)78. INSPECT FLUID LEAK (See page 51–4)79. INSPECT FRONT WHEEL ALIGNMENT (See page 26–6)80. INSTALL ENGINE UNDER COVER LH81. INSTALL ENGINE UNDER COVER RH82. CHECK ABS SPEED SENSOR SIGNAL(a) w/ VSC (See page 05–756)(b) w/o VSC (See page 05–699)83. HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65–19)

410DV–01

D30475

13 (133, 10)Hood Sub–assy

Radiator Reserve Tank Assy

Engine Cover No.1

5.0 (51, 44 in. �lbf)

7.0 (71, 62 in. �lbf)

Air Cleaner Assy

Battery ClampSub–assy

3.5 (36, 31 in. �lbf)

Battery

Battery Tray

Clip

Clip

Clip

Floor Shift TransmissionControl Cable Assy

Starter Assy

Starter Connector

Ground Cable

64 (653, 47)

80 (816, 59)

52 (530, 38)

18 (184, 13)

Manual TransmissionCase Protector

64 (653, 47)

40 (408, 30)

20 (200, 14)

8.0 (82, 71 in. �lbf)

40 (408, 30)

64 (653, 47)



12 (120, 9)

5.0 (51, 44 in. �lbf)

64 (653, 47)

Manual Transaxle Assy

13 (133, 10)

37 (380, 27)

46 (469, 34)

13 (130, 9)

Transverse Engine Engine Mounting Insulator

9.0 (92, 80 in. �lbf)

8.0 (82, 71 in. �lbf)

6.0 (61, 53 in. �lbf)

52 (530, 38)

25 (255, 18)

Air Tube No.1

25 (255, 18)



Clip

13 (131, 9)

12 (120, 9)

–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD–FTV)41–31


MANUAL TRANSAXLE ASSY (1CD–FTV)COMPONENTS

D30476


Front Drive Shaft Assy LH

� Snap Ring


Transverse EngineEngine Mounting


64 (653, 47)

� Cotter Pin

52 (530, 38)

� Cotter Pin

49 (500, 36) 8.0 (82, 71 in. �lbf)

� 216 (2,203, 159)



Engine Under Cover RHEngine Under Cover LH


64 (650, 47)

64 (650, 47)

64 (653, 47)

87 (887, 64)

64 (653, 47)

49 (500, 36)

133 (1,356, 83)

45 (459, 33)

29 (296, 21)

52 (530, 38)

74 (755, 55)

74 (755, 55)

89 (908, 66)

133 (1,356, 83)

52 (530, 38)

89 (908, 66)

35.3 (360, 26)

41–32–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD–FTV)


410DY–01

D26902

D26903



REPLACEMENT1. INSPECT CENTER FRONT WHEEL2. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50–9)3. SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50–9)4. REMOVE STEERING COLUMN HOLE COVER SUB–ASSY NO.1 (See page 50–9)5. REMOVE STEERING INTERMEDIATE SHAFT (See page 50–9)6. REMOVE FRONT WHEELS7. REMOVE ENGINE UNDER COVER RH8. REMOVE ENGINE UNDER COVER LH9. DRAIN TRANSAXLE OIL

Torque: 49 N �m (500 kgf �cm, 36 ft �lbf)10. REMOVE HOOD SUB–ASSY11. REMOVE RADIATOR SUPPORT OPENING COVER12. REMOVE ENGINE ROOM COVER SIDE13. REMOVE ENGINE COVER NO.114. REMOVE AIR CLEANER ASSY15. REMOVE BATTERY CLAMP SUB–ASSY16. REMOVE BATTERY17. REMOVE BATTERY TRAY18. REMOVE AIR TUBE NO.1 (See page 14–286)

19. SEPARATE RADIATOR RESERVE TANK ASSY(a) Remove the 2 bolts, separate the radiator reserve tank

assy.

20. REMOVE STARTER ASSY(a) Remove the nut, disconnect the starter wire.(b) Disconnect the connector.(c) Remove the 2 bolts and starter assy.

D30815

D26905

G24412

G24413



21. DISCONNECT WIRE HARNESS(a) Remove the bolt, disconnect the ground cable.(b) Remove the bolt, separate the air tube.

22. DISCONNECT CONNECTOR(a) Disconnect the back–up lamp switch connector.

23. REMOVE CLUTCH ACCUMULATOR ASSY (See page 42–22)SST 09023–00100

24. REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 42–17)SST 09023–00100

25. SEPARATE ACCUMULATOR TO FLEXIBLE HOSETUBE

(a) Remove the 3 bolts, separate the flexible hose tube withbrackets from the transaxle.

26. SEPARATE TRANSMISSION CONTROL CABLE ASSY(a) Remove the 2 clips, separate the 2 cables from the trans-


et.

27. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)SST 09520–01010, 09520–24010 (09520–32040)

28. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6)29. REMOVE HEIGHT CONTROL SENSOR SUB–ASSY FR RH (W/ DISCHARGE HEAD LAMP)

(See page 65–28)

A79193Engine Hanger No.1

Engine Hanger No.2

Engine Hanger No.1 UPR

D30072

D30073



30. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51–36)SST 09023–12700

31. DISCONNECT PRESSURE FEED TUBE ASSY (See page 51–36)SST 09023–12700

32. SUSPEND ENGINE ASSY(a) Install the 2 engine hangers with the 2 bolts.

Parts No.:No.1 engine hanger UPR (yellow) 12284–27020No.1 engine hanger UPR (black) 12284–27030No.1 engine hanger 12281–27050No.2 engine hanger (yellow) 12282–27060No.2 engine hanger (black) 12282–27070Bolt: 91642–81025Torque: 37 N �m (377 kgf �cm, 27 ft �lbf)

(b) Attach the engine chain hoist to the hanger.CAUTION:Do not attempt to hang the engine by hooking the chain toany other part.

33. REMOVE FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–26)34. SUPPORT MANUAL TRANSAXLE ASSY(a) Support the transaxle with a transmission jack.

35. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR

(a) Remove the 5 bolts, nut and engine mounting insulatorLH from the body.


(a) Remove the 3 bolts and engine mounting bracket LH fromthe transaxle.

D26918

D30076

D30074

D30075

D30075

(b)

(a)

(a)

(a)



37. REMOVE MANUAL TRANSAXLE ASSY(a) Remove the 8 bolts.(b) Remove the transaxle from the engine.

38. REMOVE MANUAL TRANSMISSION CASEPROTECTOR

(a) Remove the 2 bolts and case protector.


(a) Remove the bolt, nut and engine mounting insulator FRfrom the engine mounting bracket.

(b) Remove the 2 bolts and engine mounting bracket FR fromthe transaxle.


(a) Remove the bolt and engine mounting insulator RR fromthe engine mounting bracket.

(b) Remove the 3 bolts and engine mounting bracket RRfrom the transaxle.


(a) Install the engine mounting bracket RR and 3 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)

(b) Install the engine mounting insulator RR and bolt to theengine mounting bracket.Torque: 87 N �m (887 kgf �cm, 64 ft �lbf)

D30074

(a)

(b)

(a)

(b)

D30076

D26918

A

BC

D

E

D30073

D30072

A

A

A

A

B

A




(a) Install the engine mounting bracket FR and 2 bolts to thetransaxle.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)

(b) Install the engine mounting insulator FR, bolt and nut tothe engine mounting bracket.Torque: 52 N �m (530 kgf �cm, 38 ft �lbf)

43. INSTALL MANUAL TRANSMISSION CASEPROTECTOR

(a) Install the case protector with the 2 bolts.Torque: 18 N �m (184 kgf �cm, 13 ft �lbf)

44. INSTALL MANUAL TRANSAXLE ASSY(a) Align the input shaft with the clutch disc and install the

transaxle to the engine.(b) Install the 8 bolts.

Torque:Bolt A: 64 N �m (653 kgf �cm, 47 ft �lbf)Bolt B: 46 N �m (469 kgf �cm, 34 ft �lbf)Bolt C: 40 N �m (408 kgf �cm, 30 ft �lbf)Bolt D: 20 N �m (200 kgf �cm, 14 ft �lbf)Bolt E: 8.0 N �m (82 kgf �cm, 71 in. �lbf)


(a) Install the engine mounting bracket LH to the transaxlewith the 3 bolts.Torque: 64 N �m (653 kgf �cm, 47 ft �lbf)

46. INSTALL TRANSVERSE ENGINE ENGINE MOUNTINGINSULATOR

(a) Install the engine mounting insulator LH with the 5 boltsand nut.Torque:Bolt A: 52 N �m (530 kgf �cm, 38 ft �lbf)Bolt B: 80 N �m (816 kgf �cm, 59 ft �lbf)

G24413

G24412

A

B

D26905



47. INSTALL FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–26)SST 09670–00010

48. CONNECT PRESSURE FEED TUBE ASSY (See page 51–36)SST 09023–12700

49. CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51–36)SST 09023–12700

50. INSTALL HEIGHT CONTROL SENSOR SUB–ASSY FR RH (W/ DISCHARGE HEAD LAMP) (See page 65–28)

51. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–6)52. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–6)

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.

54. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE(a) Install the flexible hose tube with the 3 bolts.

Torque: Bolt A: 12 N �m (120 kgf �cm, 9 ft �lbf)Bolt B: 5.0 N �m (51 kgf �cm, 44 in. �lbf)Bolt C: 9.0 N �m (92 kgf �cm, 80 in. �lbf)

55. INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 42–17)SST 09023–00100

56. INSTALL CLUTCH ACCUMULATOR ASSY (See page 42–22)SST 09023–00100

57. CONNECT CONNECTOR(a) Connect the back–up lamp switch connector.

D30815

(b) (a)

D26903

D26902



58. CONNECT WIRE HARNESS(a) Install the ground cable with bolt.

Torque: 13 N �m (131 kgf �cm, 9 ft �lbf)(b) Install the air tube with bolt.


59. INSTALL STARTER ASSY(a) Connect the starter connector.(b) Install the starter assy to the transaxle with the 2 bolts.

Torque: 37 N �m (380 kgf �cm, 27 ft �lbf)(c) Install the starter wire to starter assy with the nut.


60. CONNECT RADIATOR RESERVE TANK ASSY(a) Install the radiator reserve tank assy with the 2 bolts.

Torque: 6.0 N �m (61 kgf �cm, 53 in. �lbf)

61. INSTALL AIR TUBE NO.1 (See page 14–286)62. INSTALL BATTERY TRAY63. INSTALL BATTERY64. INSTALL BATTERY CLAMP SUB–ASSY

Torque:Bolt: 5.0 N �m (51 kgf �cm, 44 in. �lbf)Nut: 3.5 N �m (36 kgf �cm, 31 in. �lbf)

65. INSTALL AIR CLEANER ASSYTorque: 7.0 N �m (71 kgf �cm, 62 in. �lbf)

66. INSTALL ENGINE COVER NO.1Torque: 8.0 N �m (82 kgf �cm, 71 in. �lbf)

67. INSTALL STEERING INTERMEDIATE SHAFT (See page 50–9)68. INSTALL STEERING COLUMN HOLE COVER SUB–ASSY NO.1 (See page 50–9)69. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50–9)70. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50–9)71. PLACE FRONT WHEELS FACING STRAIGHT AHEAD72. STEERING WHEEL CENTER POINT73. INSTALL ENGINE ROOM COVER SIDE74. INSTALL RADIATOR SUPPORT OPENING COVER



75. INSTALL HOOD SUB–ASSYTorque: 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 FLUID81. 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 RH87. INSTALL ENGINE UNDER COVER LH88. 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)

410DS–01

D30478

Battery Clamp Sub–assy

Battery Tray

Charcoal Canister AssyBattery Carrier


Clip

Air Cleaner Assy

Hood Sub–assy

Cylinder Head Cover No.2

Starter Assy

Back–up Lamp SwitchConnector


Clip

Clip

Clip

Clip

37 (380, 27)

Starter Connector


52 (530, 38)

52 (530, 38)

Ground Cable

� Gasket

7.0 (71, 62 in. �lbf)

Filler Plug

37 (380, 27)

23 (230, 17)

47 (479, 35)


19 (195, 14)

13 (130, 9)

64 (653, 47)

64 (653, 47)

5.0 (51, 44 in. �lbf)


5.0 (51, 44 in. �lbf)

14 (141, 10)

13 (133, 10)

13 (131, 9)

5.0 (51, 44 in. �lbf)

26 (260, 19)

25 (255, 18)

80 (816, 59)

26 (260, 19)

23 (230, 17)



40 (410, 30)

39 (400, 29)Manual Transaxle Assy

64 (653, 47)

Battery

Clutch Release Cylinder Assy

–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ–FE/3ZZ–FE)41–13


MANUAL TRANSAXLE ASSY (1ZZ–FE/3ZZ–FE)COMPONENTS

D30479


� Snap RingFront Drive

� Snap Ring



64 (653, 47)

87 (887, 64)Transverse EngineEngine Mounting Bracket

� Cotter Pin

64 (653, 47)

52 (530, 38)

� Cotter Pin

Engine Under Cover RH



64 (653, 47)

� 216 (2,203, 159)45 (459, 33)

Engine Under Cover LH

35 (360, 26)

74 (755, 55)

52 (530, 38)

49 (500, 36)

133 (1,356, 83)

29 (296, 21)

49 (500, 36)

74 (755, 55)

89 (908, 66)

8.0 (82, 71 in. �lbf)

133 (1,356, 83)

89 (908, 66)

41–14–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ–FE/3ZZ–FE)


4100Z–05

D25304

0 to 5 mm(0 to 0.20 in.)

41–2–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE OIL (MTM)


MANUAL TRANSAXLE OIL (MTM)ON–VEHICLE INSPECTION

1. INSPECT TRANSAXLE OIL(a) Stop the vehicle on the level place.(b) Remove the transmission filler plug and gasket.(c) Check that the oil surface is within 5 mm (0.20 in.) from the

lowest position of the inner surface of the transmission fill-er plug opening.

NOTICE:� Excessively large or small amount of oil may cause

troubles.� 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 N�m (400 kgf �cm, 29 ft �lbf)E354, E357: 49 N�m (500 kgf �cm, 36 ft �lbf)

4100Y–05

–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM (MTM)41–1


MANUAL TRANSAXLE SYSTEM (MTM)PROBLEM SYMPTOMS TABLEUse the table below to help find the cause of the problem. The numbers indicate the likelihood of the possiblecause in descending order. Check each part in the order shown. Replace these parts as necessary.�: (C50 MANUAL TRANSAXLE Repair Manual Pub. No. 826E or C250 MANUAL TRANSAXLE RepairManual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E)

Symptom Suspect Area See page

Noise

6. Oil (Level low)

7. Oil (Wrong) C50/C250

E354/E357

8. Gear (Worn or damaged)

9. Bearing (Worn or damaged)

41–2

41–3

41–5

�

�

Oil leakage

1. Oil (Level too high)

2. Gasket (Damaged)

3. Oil seal (Worn or damaged) C50/ C250

E354/E357

4. O–Ring (Worn or damaged)

41–2

�

41–3

41–5

�

Hard to shift or will not shift

1. Control cable (Faulty)

2. Synchronizer ring (Worn or damaged)

3. Shift key spring (Damaged)

41–7

�

�

Jumps out of gear

1. Locking ball spring (Damaged)

2. Shift fork (Worn)

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

�

�

�

�

4105R–02

D30060

1ZZ–FE, 3ZZ–FE:

1AZ–FE, 1AZ–FSE, 1CD–FTV:

D30070

–MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)41–7


TRANSMISSION CONTROL CABLE ASSY (MTM)REPLACEMENTHINT:COMPONENTS: See page 41–101. REMOVE AIR CONDITIONER UNIT ASSY (See page 55–55)HINT:Refer to the instructions for removal of the instrument panel sub–assy lower.2. REMOVE EXHAUST PIPE ASSY(a) 1ZZ–FE, 3ZZ–FE Engine (See page 15–2)(b) 1AZ–FE, 1AZ–FSE Engine (See page 15–7)(c) 1CD–FTV Engine (See page 15–10)3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)(a) Remove the 3 nuts and heat insulator No.1.

4. REMOVE TRANSMISSION CONTROL CABLE ASSY(a) Remove the 2 clips, separate the 2 cables from the trans-


et.

(c) Remove the 2 nuts, separate the control cable assy.

D30071

D26893

D26895

D30071

D26972

41–8–MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)


(d) Remove the 2 bolts, separate the control cable assy.

(e) Remove the 2 clips, separate the cable ends of the controlcable assy.

(f) Release the claws, remove the control cable assy.

5. INSTALL TRANSMISSION CONTROL CABLE ASSY(a) Put the control cable assy through the floor hole.(b) Install the control cable assy with the 2 bolts.

Torque: 5.0 N �m (51 kgf �cm, 44 in. �lbf)

(c) Connect the control cable assy to the shift lever assy.NOTICE:Make sure that the claws are firmly engaged.

D26894

Serrate Part

D30070

D30060

1ZZ–FE, 3ZZ–FE:

1AZ–FE, 1AZ–FSE, 1CD–FTV:

–MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)41–9


(d) Connect the end of the select cable to the shift lever assyand install the clip.

NOTICE:� The serrate part of the select cable point should face

upward when the select cable point is connected.� 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.

(f) Connect the control cable assy with the 2 nuts.Torque: 5.0 N �m (51 kgf �cm, 44 in. �lbf)

(g) Connect the 2 cable ends, install the 2 clips.(h) Install the 2 clips to the control cable bracket.

6. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)(a) Install the heat insulator No.1 with the 3 nuts.

Torque: 5.5 N �m (56 kgf �cm, 49 in. �lbf)7. INSTALL EXHAUST PIPE ASSY(a) 1ZZ–FE, 3ZZ–FE Engine (See page 15–2)(b) 1AZ–FE, 1AZ–FSE Engine (See page 15–7)(c) 1CD–FTV Engine (See page 15–10)

Documents

FLOOR SHIFT SHIFT LEVER ASSY (MTM) - …docshare01.docshare.tips/files/10714/107141512.pdf · d26972 d26894 serrate part 41–12 manual transmission/transaxle – floor shift shift