TOYOTA AVENSIS 2005 Service Repair Manual

D30351
D30861
B
A
A
AA
C85797
C80168
A
A
BC
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
40±33
AVENSIS REPAIR MANUAL (RM1018E)
45. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket LH and 3 bolts to the
automatic transaxle.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
46. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Install the engine mounting insulator LH, 5 bolts and nut. Torque:
Bolt A: 52 N
m (530 kgf
cm, 38 ft
lbf)
Nut B: 80 N
m (816 kgf
cm, 59 ft
lbf)
47. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Install the bolt and nut to the engine mounting bracket FR. Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
48. INSTALL ENGINE MOUNTING MEMBER SUB±ASSY CENTER
(a) Install the center member and 4 bolts. Torque:
Bolt A: 45 N
m (459 kgf
cm, 33 ft
lbf)
Bolt B: 96 N
m (979 kgf
cm, 71 ft
lbf)
Bolt C: 52 N
m (530 kgf
cm, 38 ft
lbf)
49. INSTALL STARTER ASSY
(a) Install the starter with the 2 bolts. Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
(b) Connect the connecter.
(c) Install the starter wire with the nut. Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
50.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
51.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
52.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
53. INSTALL FRONT WHEELS

D30345
D30344
B
AA
D30346
D30343
40±34
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
54. INSTALL OIL COOLER OUTLET TUBE NO.1
(a) Using SST, tighten the oil cooler outlet tube No.1.
Torque: 34 N
m (347 kgf
cm, 25 ft
lbf)
SST 09023±12700
55. INSTALL OIL COOLER INLET TUBE NO.1
(a) Using SST, tighten the oil cooler inlet tube No.1.
Torque: 34 N
m (347 kgf
cm, 25 ft
lbf)
SST 09023±12700
56. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Install the transmission control cable bracket No.1 and
clamp and 3 bolts to the automatic trasaxle.
Torque:
Bolt A: 12 N
m (122 kgf
cm, 8 ft
lbf)
Bolt B: 5.4 N
m (55 kgf
cm, 47 ft
lbf)
57. INSTALL TRANSMISSION OIL FILLER TUBE
SUB±ASSY
(a) Coat a new O±ring with ATF, and install it to the oil filler
tube.
(b) Install the oil filler tube and bolt to the automatic transaxle.
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(c) Install the ATF level gauge.
58. INSTALL TRANSMISSION CONTROL CABLE CLAMP
(a) Install the transmission control cable clamp and bolt to the
automatic transaxle.
Torque: 12 N
m (122 kgf
cm, 8 ft
lbf)

D30342
D30341
BA
A
C81535
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
40±35
AVENSIS REPAIR MANUAL (RM1018E)
59. CONNECT CONNECTOR
(a) Connect the 2 clamps to the oil filler tube.
(b) Connect the transmission wire connector.
(c) Connect the park/neutral position switch connector.
(d) Connect the 2 speed sensor connectors.
60. INSTALL WIRE HARNESS
(a) Install the 2 wire harnesses and wire harness bracket with
the 3 bolts.
Torque:
Bolt A: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Bolt B: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
61. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Temporarily install the control cable to the control shaft le- ver with nuts.
(b) Install the control cable and clip to the bracket.
62. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (50 kgf
cm, 44 in.
lbf)
63. INSTALL BATTERY CARRIER Torque: 13 N
m (132 kgf
cm, 10 ft
lbf)
64. INSTALL BATTERY
65. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
66. INSTALL HOOD SUB±ASSY
Torque: 13 N
m (132 kgf
cm, 10 ft
lbf)
67.INSPECT HOOD SUB±ASSY (See page 75±2)
68.ADJUST HOOD SUB±ASSY (See page 75±2)
69. ADD COOLANT
(a)1AZ±FE (See pege 16±13)
(b)1AZ±FSE (See pege 16±25)
70. ADD AUTOMATIC TRANSAXLE FLUID
71.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
72.ADJUST SHIFT LEVER POSITION (See page 40±69)
73.INSPECT SHIFT LEVER POSITION (See page 40±69)
74.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
75. CHECK ABS SPEED SENSOR SIGNAL

40±36
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
(a)ABS WITH EBD SYSTEM (See pege 05±699)
(b)ABS WITH EBD & BA &TRAC & VSC SYSTEM (See pege 05±756)
76. RESET MEMORY
(a)1AZ±FE (See pege 05±863)
(b)1AZ±FSE (See pege 05±920)

40120±01
D30355
: Specified torqueBattery
13 (132, 10)
Automatic
Transaxle Assy
ATF Level Gauge
9.8 (100, 87 in.
lbf)
Transmission
Oil Filler Tube
Sub±assy
37 (377, 27)5.5 (56, 49 in.
lbf)
Starter Assy
12 (122, 9)
Clip
Transmission Control
Cable Assy
12 (122, 8)
7.0 (71, 62 in.
lbf)
Hood Sub±assyEngine Room Cover Side
Radiator Suppot
OpeningCover
Air Cleaner Assy
5.0 (50, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
12 (122, 8)
8.4 (86, 74 in.
lbf)

Non±reusable Part
O±ring
Transmission Control
Cable Clamp
Transmission Control
Cable Bracket No.1
5.4 (55, 47 in.
lbf)
Oil Cooler Inlet Tube No.1
34 (347, 25)
Oil Cooler
Outlet Tube No.1
Engine Cover
Sub±assy No.1
1AZ±FSE
N
m (kgf
cm, ft
lbf)
Battery Carrier
13 (132, 100)
13 (132, 100)
Clamp
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±23
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSAXLE ASSY (U241E)
COMPONENTS

D30356
x6

Gasket

Non±reusable Part: Specified torque
Torque Converter Clutch Assy
41 (420, 30)
Flywheel Housing
Under Cover
44 (449, 32)
46 (470, 34)
44 (449, 32)
Engine Under Cover RH
Engine Under Cover LH
Engine Mounting
Bracket FR
52 (530, 38)
64 (653, 47)
64 (653, 17)
45 (459, 33)
Engine Mounting Member Sub±Assy Center
96 (979, 71)
52 (530, 38)
52 (530, 38)64 (653, 47)
87 (887, 64)
Engine Mounting
Bracket RR
64 (653, 47)
Engine
Mounting
Insulator RR
Front Drive
Shaft Assy LH
Automatic Transaxle Assy

Snap Ring
Gasket
Exhaust Pipe
Assy Front
52 (530, 38)64 (650, 47)
80 (815, 59)
Engine
Mounting
Insulator LH
52 (530, 38)64 (653, 47)
Engine Mounting
Bracket LH
Drain Plug
N
m (kgf
cm, ft
lbf)
46 (470, 34)
49 (500, 36)


Front Drive Shaft Assy RH
64 (650, 47)
64 (650, 47)
64 (650, 47)
40±24
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)

4011Z±02
D30480
C81535
C91885
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
40±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE HOOD SUB±ASSY
2. REMOVE CYLINDER HEAD COVER NO.2
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE BATTERY
6. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier and clamp.
7. REMOVE AIR CLEANER ASSY
8. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the nut from the control shaft lever.
(b) Separate the control cable from the control shaft lever.
(c) Remove the clip and disconnect the control cable from
the control cable bracket.
9. REMOVE TRANSMISSION CONTROL CABLE CLAMP
(a) Disconnect the wire harness clamp and control cable
from the control cable clamp.
(b) Remove the bolt and control cable clamp.

C91880
C80991
C91884
40±12
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
10. SEPARATE WIRE HARNESS
(a) Remove the bolt and disconnect the wire harness.
(b) Remove the bolt and disconnect the wire harness clamp bracket.
11. SEPARATE CONNECTOR
(a) Disconnect the transmission wire connector.
(b) Disconnect the park/neutral position switch connector.
(c) Disconnect the speed sensor connector.
12. REMOVE ENGINE UNDER COVER RH
13. REMOVE ENGINE UNDER COVER LH
14.DRAIN COOLANT (See page 16±7) 15. DISCONNECT OIL COOLER INLET TUBE NO.1
(a) Using SST, disconnect the oil cooler inlet tube No.1.SST 09023±12700
16. DISCONNECT OIL COOLER OUTLET TUBE NO.1
(a) Using SST, disconnect the oil cooler outlet tube No.1. SST 09023±12700
17. REMOVE TRANSMISSION OIL FILLER TUBESUB±ASSY
(a) Remove the ATF level gauge.
(b) Remove the 2 bolts, oil cooler tube clamp and oil filler
tube.
(c) Remove the breather hose from the oil filler tube.
(d) Remove the O±ring from the oil filler tube.

C91882
C94723
D25372
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
40±13
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Disconnect the wire harness clamp.
(b) Remove the 2 bolts and control cable bracket.
19. SEPARATE WIRE HARNESS
(a) Remove the bolt and wire harness.
20. SUSPEND ENGINE ASSY
(a) Install the No.1 and No.2 engine hangers in the correct
direction.
Parts No.:
No.1 engine hanger: 12281±22021
No.2 engine hanger: 12281±15040
Bolt: 91512±B1016
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Attach the engine chain hoist to the engine hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other parts.
21. REMOVE FRONT WHEELS
22. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and the drain plug. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
23.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±2)
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) SST 09520±01010, 09520±24010 (09520±32040)
26. REMOVE STARTER ASSY
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter.
27. SUPPORT AUTOMATIC TRANSAXLE ASSY
(a) Support the automatic transaxle with a transmission jack.

D31010
D30349
D30350
C87421
D25738
40±14
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
28. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the bolt and disconnect the wire harness clamp
bracket.
(b) Remove the 4 bolts, nut and engine mounting insulator
LH.
29. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH.
30. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the bolt from the engine mounting bracket RR.
(b) Remove the 3 nuts, bolt and engine mounting insulator
RR from the suspension member.