TOYOTA AVENSIS 2005 Service Repair Manual

4006W±01
C83132
Match±marks
C83133
C83134
D25211
SST
40±100
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
FRONT DIFFERENTIAL ASSY (U241E)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match±marks on the ring gear and differential
case.
(b) Remove the 10 bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the case.
2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case tapered roll-
er bearing front inner race from the differential case.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04020, 09954±04010, 09955±04061,
09957±04010, 09958±04011), 09950±60010
(09951±00340)

D25212
SST
D25213
SST
D25214
SST
C59843
C59998
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
40±101
U241E A/T REPAIR MANUAL (RM840U)
(b) Using SST, remove the front differential case tapered roll-
er bearing front outer race and differential case washer.
SST 09387±00040 (09387±01030, 09387±01040,
09387±02010, 09387±02020)
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case tapered roll-
er bearing rear inner race from the differential case.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04020, 09954±04010, 09955±04061,
09957±04010, 09958±04011), 09950±60010
(09951±00340)
(b) Using SST, front differential case tapered roller bearing
rear outer race and differential case washer.
SST 09387±00040 (09387±01030, 09387±01040,
09387±02010, 09387±02020)
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a punch and a hummer, loosen the staked part of
the differential case.
(b) Using a pin punch (5 mm), drive out the pin from ring gear
side.

C83135
C83136
D25600
SST
D25599
SST
C83137
40±102
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No. 1 from the
differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion thrust
washers, 2 front differential side gears and 2 side gear
thrust washers from the differential case.
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Place the transaxle case in vise.
(b) Using SST, remove the oil seal.
SST 09308±00010
8. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Place the transaxle housing in vise.
(b) Using SST, remove the oil seal.
SST 09308±00010
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear thrust
washers, 2 front differential pinions and 2 pinion thrust
washers with ATF and install them to the differential case.

C83135
C83138
C60005
C60006
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
40±103
U241E A/T REPAIR MANUAL (RM840U)
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Coat the front differential pinion shaft No. 1 with ATF and
install it to the differential case.
11. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Using a dial indicator, inspect the backlash of the side
gear.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
Thrust washer thickness:
MarkThickness
±1.0 mm (0.0394 in.)
±1.1 mm (0.0433in.)
±1.2 mm (0.0472 in.)
±1.3 mm (0.0512 in.)
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the pinion shaft
straight pin.
(b) Using a chisel and hammer, stake the differential case.

D25218
SST
D25219
SST
D25216
SST
D25217
SST
D25215
90 ± 100
C (194 ± 230
F) 40±104
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
13. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing rear inner race to the differential
case.
SST 09608±06041
(b) Using SST and a hammer, install the case washer and
front differential case tapered roller bearing rear outer
race to the transaxle case.
SST 09950±60020 (09951±00710), 09950±70010
(09951±07100)
14. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09608±06041
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07100), 09950±60010 (09951±00340)
15. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and hear, hear the front differential ring gear
to 90 ± 110
C (194.0 ± 230.0
F).
(b) Clean the contact surface of the front differential case.

C83132
Match±marks
C83133
C83139
C50259
C
C
C
CA
AA B
BB
C83572
SST
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
40±105
U241E A/T REPAIR MANUAL (RM840U)
(c) Set the match±marks, install the front differential ring gear
case quickly.
(d) Tighten the 10 bolts.
Torque: 95 N
m (969 kgf
cm, 70 ft
lbf)
16. INSPECT TAPERED POLLER BEARING PRELOAD
(a) Install the differential assy to the transaxle case.
(b) Install the transaxle housing to the transaxle case.
(c) Install the 16 bolts.
Torque:
Bolt A, B: 29.4 N
m (300 kgf
cm, 21.7 ft
lbf)
Bolt C: 22.1 N
m (225 kgf
cm, 16.3 ft
lbf)
BoltBolt length (mm)
A, B42
C50
(d) Using SST, turn the differential assy.
SST 09564±32011

C83572
SST
D09182
C83139
40±106
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(e) Using SST and torque wrench, measure the preload of
the differential assy.
SST 09564±32011
Preload
New bearing:
0.20 ± 0.69 N
m (2.0 ± 7.0 kgf
cm, 1.8 ± 6.1 in.
lbf)
Used bearing:
0.10 ± 0.35 N
m (1.0 ± 3.6 kgf
cm, 0.9 ± 3.1 in.
lbf)
Adjusting shim thickness: mm (in.)
MarkThickness
01.90 (0.074)
11.95 (0.077)
22.00 (0.079)
32.05 (0.081)
42.10 (0.083)
52.15 (0.085)
62.20 (0.087)
72.25 (0.089)
82.30 (0.091)
92.35 (0.093)
A2.40 (0.094)
B2.45 (0.096)
C2.50 (0.098)
D2.55 (0.100)
E2.60 (0.102)
F2.65 (0.104)
G2.70 (0.106)
H2.75 (0.108)
J2.80 (0.110)
(f) Remove the 16 bolts.
(g) Using a practice hammer, remove the transaxle housing.
(h) Remove the differential assy.

D25606
SST
D25605
SST
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
40±107
U241E A/T REPAIR MANUAL (RM840U)
17. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST, drive into a new oil seal.
SST 09350±32014 (09351±32150), 09950±70010
(09951±07150)
(b) Coat the rip of oil seal with a little MP grease.
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, drive into a new oil seal.
SST 09350±32014 (09351±32150), 09950±70010
(09951±07150)
(b) Coat the rip of the oil seal with a little MP grease.

020JR±01
02±6
± PREPARATIONSTARTING & CHARGING
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
STARTING & CHARGING
PREPARATION
SST
09820±63010Alternator Pulley Set Nut Wrench
SetGENERATOR ASSY(1AZ±FE)
(09820±06010)Alternator Rotor Shaft WrenchGENERATOR ASSY(1AZ±FE)
(09820±06020)Alternator Pulley Set Nut 22 mm
WrenchGENERATOR ASSY(1AZ±FE)
Recomended Tools
09082±00040TOYOTA Electrical TesterSTARTER ASSY(1.3KW)(1AZ±FE)
Equipment
V±block
Dial indicator
Ohmmeter
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Press

140DW±01
A13845
A13846
A13848
A13874
14±42
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
CYLINDER BLOCK (1AZ±FE)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.160 ± 0.362 mm (0.0063 ± 0.0143 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
(b) If the thrust clearance is greater than maximum, replace
the connecting rod assembly(s). If necessary, replace the
crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
HINT:
The connecting rod cap bolts are tightened in 2 progressive
steps.
(a) Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of plastigage on the crank pin.
(f) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(g) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(h) Tighten the bolts in several passes by the specified
torque.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)