TOYOTA AVENSIS 2005 Service Repair Manual

C80166
C95354
D30347
D30348
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
40±15
AVENSIS REPAIR MANUAL (RM1018E)
31. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the bolt and nut from the engine mounting brack-
et FR.
32. REMOVE ENGINE MOUNTING MEMBER SUB±ASSY
CENTER
(a) Remove the 4 bolts and center member with engine
mounting insulator FR.
33. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 2 bolts and engine mounting bracket FR.
34. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket RR.
35. REMOVE FLYWHEEL HOUSING UNDER COVER
(a) Remove the flywheel housing under cover from the automatic transaxle.

C91990
C67029
C63993
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±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
36. REMOVE AUTOMATIC TRANSAXLE ASSY
(a) Turn the crankshaft to remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.
(b) Remove the 6 bolts.
(c) Separate and remove the automatic transaxle.
37. REMOVE TORQUE CONVERTER CLUTCH ASSY
38.INSPECT TORQUE CONVERTER CLUTCH ASSY (See page 40±37) SST 09350±32014 (09351±32010, 09351±32020) 39. INSTALL TORQUE CONVERTER CLUTCH ASSY
(a) Install the torque converter clutch to the automatic trans-axle.
(b) Using vernier calipers, measure the dimension ºAº be- tween the trasaxle fitting part and the converter fitting part
of the drive plate.

C65911

D30888
A A
C
C B
B
C91990
D30348
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
40±17
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using vernier calipers and a straight edge, measure the
dimension ºBº shown in the illustration and check that ºBº
is greater than ºAº measured in (b).
Standard: A + 1 mm or more
NOTICE:
Do not add the thickness of the straight edge.
40. INSTALL AUTOMATIC TRANSAXLE ASSY
(a) Install the automatic transaxle and 6 bolts to the engine.
Torque:
Bolt A: 64 N
m (650 kgf
cm, 47 ft
lbf)
Bolt B: 46 N
m (470 kgf
cm, 34 ft
lbf)
Bolt C: 23 N
m (235 kgf
cm, 17 ft
lbf)
(b) Install the 6 torque converter mounting bolts.
Torque: 28 N
m (285 kgf
cm, 20 ft
lbf)
HINT:
First install yellowish green colored bolt, and then the the 5
bolts.
41. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover to the automatic transaxle.
42. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket RR and 3 bolts to the
automatic trasaxle.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)

D30347
C95354C
B
A
A

C80869
D25738


C80870
40±18
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
43. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
automatic trasaxle.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
44. INSTALL ENGINE MOUNTING MEMBER SUB±ASSY
CENTER
(a) Install the dynamic damper, member sub±assy center
with the engine mounting insulator FR 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)
45. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
INSULATOR
(a) Install the engine mounting insulator RR and bolt to the
engine mounting bracket RR.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(b) Tighten the 3 nuts and bolt.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
46. 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)

D30350
D30349
D31010
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
40±19
AVENSIS REPAIR MANUAL (RM1018E)
47. 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)
48. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Install the engine mounting insulator LH, 4 bolts and nut. Torque:
Bolt : 52 N
m (530 kgf
cm, 38 ft
lbf)
Nut : 80 N
m (815 kgf
cm, 59 ft
lbf)
(b) Install the wire harness clamp bracket and bolt.
49. INSTALL STARTER ASSY
(a) Install the starter and 2 bolts. Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
(b) Connect the connector.
(c) Install the starter wire and nut.
Torque: 13 N
m (132 kgf
cm, 10 ft
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±2)
53. INSTALL FRONT WHEELS

C94723
C91882

C87398
A
B
C80991
40±20
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
54. INSTALL WIRE HARNESS
(a) Install the wire harness clamp bracket and bolt.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
55. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Install the control cable bracket and 2 bolts.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
56. INSTALL TRANSMISSION OIL FILLER TUBE
SUB±ASSY
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.
(c) Coat a new O±ring with ATF, and install it to the oil filler
tube.
(d) Install the oil filler tube to the automatic transaxle.
(e) Install the oil cooler tube clamp and 2 bolts.
Torque:
Bolt A: 12 N
m (122 kgf
cm, 9 ft
lbf)
Bolt B: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(f) Install the ATF level gauge.
57. CONNECT OIL COOLER OUTLET TUBE NO.1
(a) Using SST, tighten oil cooler outlet tube No.1.
Torque: 35 N
m (357 kgf
cm, 25 ft
lbf)
SST 09023±12700
58. CONNECT OIL COOLER INLET TUBE NO.1
(a) Using SST tighten the oil cooler inlet tube No.1.
SST 09023±12700
Torque: 35 N
m (357 kgf
cm, 25 ft
lbf)

C91880
C91885
C81535
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
40±21
AVENSIS REPAIR MANUAL (RM1018E)
59. INSTALL WIRE HARNESS
(a) Install the wire harness and bolt.
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
(b) Install the wire harness clamp bracket and bolt. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbff)
60. INSTALL TRANSMISSION CONTROL CABLE CLAMP
(a) Install the control cable support and bolt. Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
(b) Connect the control cable and wire harness to the control cable support.
61. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Temporarily install the control cable to the control shaft le- ver with the nut.
(b) Install the control cable and clip to the bracket.
62. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
63. INSTALL BATTERY CARRIER Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
64. INSTALL BATTERY
65. INSTALL ENGINE ROOM COVER SIDE
66. INSTALL RADIATOR SUPPORT OPENING COVER
67. INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
68. INSTALL HOOD SUB±ASSY Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
69.INSPECT HOOD SUB±ASSY (See page 75±2)
70.ADJUST HOOD SUB±ASSY (See page 75±2)
71. ADD AUTOMATIC TRANSAXLE FLUID
72.ADD COOLANT (See page 16±1)
73.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
74.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
75.ADJUST SHIFT LEVER POSITION (See page 40±69)
76.INSPECT SHIFT LEVER POSITION (See page 40±69)
77.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)

40±22
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
78.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)
79.RESET MEMORY (See page 05±985)

4011Y±01
D30353
Hood Sub±assy
BatteryAir Cleaner Assy
Non±reusable part
: Specified torque


5.0 (51, 44 in.
lbf)
13 (132, 10)
7.0 (71, 62 in.
lbf)
12 (122, 9)
5.0 (51, 44 in.
lbf)26 (265, 19)
39 (409, 29)
39 (400, 29)
Engine Room Cover Side
Radiator Suppot Opening Cover
O±ring
Transmission Oil Filler
Tube Sub±assy
Oil Cooler Inlet Tube No.1
13 (132, 10)Starter Assy Cylinder Head
Cover No.2
5.5 (51, 44 in.
lbf)
12 (122, 9)
Oil Cooler Outlet Tube No.1
35 (357, 25)
ATF Level Gauge
Transmission Control Cable Bracket
12 (122, 9)
12 (122, 9)
Clip
Transmission
Control Cable Assy
11 (110, 8)
Automatic
Transaxle
Assy
Transmission Control
Cable Clamp
Oil Cooler
Tube Clump
N
m (kgf
cm.
ft
lbf)
Battery Carrier
13 (131, 9)
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
40±9
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSAXLE ASSY (U341E)
COMPONENTS

D30354
Front Drive Shaft Assy RH

Snap Ring
Torque Converter Clutch Assy
x6
Flywheel Housing
Under Cover
Engine Under Cover RH
Engine Under Cover LH
Engine Mounting
Bracket FR
Engine Mounting Member Sub±assy Center Engine Mounting Bracket RR Drain Plug
GasketAutomatic Transaxle AssyFront Drive
Shaft Assy LH
Gasket

Snap RingExhaust Pipe
Assy FrontEngine
Mounting
Insulator LH Engine Mounting
Bracket LH

Non±reusable Part: Specified torqueEngine Mounting Insulator RR64 (653, 47)
80 (815, 59)
52 (530, 38)
64 (650, 47)
28 (285, 20)
46 (470, 34)
23 (235, 17)
52 (530, 38)
49 (500, 36)87 (887, 64)
64 (653, 47)
52 (530, 38)
64 (653, 17)
64 (653, 47)52 (530, 38)
52 (530, 38)
52 (530, 38)
96 (979, 71)45 (459, 33)
64 (653, 47)
N
m (kgf
cm.
ft
lbf)
40±10
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)