manual transmission TOYOTA AVENSIS 2005 Service Repair Manual

140D1±02
CG
TCA51075
A52004
±
ENGINE MECHANICAL ENGINE(1AZ±FE)
14±101
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±13)
2.INSPECT ENGINE OIL (See page 17±6)
3. INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±9)
6. INSPECT V±RIBBED BELT
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using hand±held tester:(1) Connect the hand±held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF.
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.

141CP±01
CG
TCA51075
A79034
±
ENGINE MECHANICAL ENGINE(1AZ±FSE)
14±181
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FSE)
INSPECTION
1.INSPECT COOLANT (See page 16±25)
2.INSPECT ENGINE OIL(See page 17±13)
3.INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±14)
6.INSPECT V±RIBBED BELT
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040, 09843±18020
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed. (5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.

A77298
LHD Steering Position typeRHD Steering Position type
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±207
AVENSIS REPAIR MANUAL (RM1018E)
39.REMOVE FRONT AXLE HUB RH NUT
SST09330±00030
HINT:
Perform the same procedure as above on the opposite side.
40.SEPARATE TIE ROD END SUB±ASSY LH (See page 51±36)
41.SEPARATE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
42.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
43.SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
44.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
(See page 26±21)
45.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) (See page 26±16)
46.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
47.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
48.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
49.SEPARATE FRONT AXLE ASSY RH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side. 50.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
(a)Remove the 7 bolts shown in the illustration.
51.SEPARATE TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
52.SEPARATE TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)

A77404
B
A
BBBB
A
B
A77304
A77305
A77405
A
B
A
A
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±215
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the front suspension member braces with the 8
bolts.
Torque:
Bolt A 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B 80 N
m (816 kgf
cm, 59 ft
lbf)
132.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
133.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
134.INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
135.REMOVE ENGINE HANGERS
136.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
137.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
138.INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)

A77314
A/T:
Clip
Transmission
Control Cable Assy
N´m (kgf´cm, ft´lbf)
: Specified torque
M/T:
Transmission Control
Cable Assy
5.0 (51, 44 in.
lbf)
12 (120, 9.0)
M/T:
Clutch Release
Cylinder Assy
12 (122, 8.9)
Clip
5.0 (51, 44 in.
lbf)
9.0 (92, 80 in.
lbf)
14±196
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A79419
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
29 (296, 21)
80 (816, 59)
133 (1,348, 97)
43 (440, 32)
30 (302, 22)
43 (440, 32)

Gasket
74 (755, 55)
49 (500, 36)

Gasket
Cotter Pin V (Cooler Compressor
to Crankshaft pulley)
Belt No. 1Glove Compartment Door Assy
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silencer Sheet
Front Stabilizer Link Assy LHClip
Tie Rod End Sub±assy LH
Front Axle Hub LH Nut
Front Suspension Member
Brace Rear LH
Compression
Spring
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring w/ A/C:
Compressor And Magnetic ClutchFront Drive Shaft Assy LHClip Transmission Control
Cable Assy
Clip
Clutch Accumulator Assy
Clutch Release Cylinder Assy
Transmission Control Cable Assy
35 (357, 26)
142 (1,448, 105)
Clip
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±279
AVENSIS REPAIR MANUAL (RM1018E)

A79178
A78277
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±287
AVENSIS REPAIR MANUAL (RM1018E)
24.SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a)Remove the 2 clips and 2 washers, separate the control cable assy.
25.REMOVE INJECTOR DRIVER
(a)Remove the 2 nuts which is used to secure the injector driver.
(b)Disconnect the injector driver connector and the harness clamp.
(c)Remove the injector driver.
26.DISCONNECT ENGINE WIRE
(a)Remove the glove compartment door.
(b)Disconnect the engine wire from the ECM and the junc-
tion block.
(c)Pull out the engine wire.
(d)Disconnect the engine wire from engine room junction block.
(e)Remove the bolt and disconnect the wire harness from the body.
27.REMOVE AIR TUBE NO.1
(a)Loosen the hose clamps.
(b)Remove the 2 bolts and nut, and then detach the air tube No. 1.
28.REMOVE CLUTCH ACCUMULATOR ASSY (See page 42±17) SST 09023±00100
29.REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 42±17)
30. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
31. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See page 55±86)
HINT:
Secure the hoses off to the side instead of detaching.
32.REMOVE FLOOR PANEL BRACE FRONT (See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±10)

16±20
±
COOLING ENGINE COOLANT(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
2.ADD ENGINE COOLANT
(a)Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD6.0 (6.3, 5.3)
M/TRHD6.1 (6.4, 5.4)
A/TLHD6.3 (6.7, 5.5)
A/TRHD6.4 (6.8, 5.6)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's directions.

Using of coolant with includes more than 50 % (freezing protection down to ±\
35 C (±31 F)) or 60 %
(freezing protection down to ±50 C (±58 F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times with hard.

If the coolant level gets lower, pour coolant.
(b)Reinstall the radiator cap.
(c)Pour engine coolant into the reservoir tank until it reaches full line.
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times with hard during \
the warming up.
(e)Stop the engine and wait until the coolant temp. Gets cold. Then remove the radiator cap to check the coolant level.
HINT:

If the level gets lower, perform the procedures above again.

If the level does not gets lower, adjust the reservoir tank coolant level.
3.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)

160MH±01
A64364
Radiator CapCylinder Block
Drain Cock Plug
Drain Pipe
Radiator
Drain Cock Plug
± COOLINGENGINE COOLANT (1ZZ±FE/3ZZ±FE)
16±7
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1ZZ±FE/3ZZ±FE)
REPLACEMENT
1. DRAIN ENGINE COOLANT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(a) Remove the radiator cap.
(b) Loosen the radiator drain cock plug and the cylinder block
drain cock plug, and drain engine coolant.
(c) Close the radiator drain cock plug.
(d) Close the cylinder block drain plug.
Torque: 13 N
m (130 kgf
cm, 9 ft
lbf) for engine
2. ADD ENGINE COOLANT
(a) Tighten the radiator drain plug, and pour coolant into radiator until it overflows.
Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD5.8 (6.1, 5.1)
M/TRHD5.9 (6.2, 5.2)
A/TLHD5.7 (6.0, 5.0)
A/TRHD5.8 (6.1, 5.1)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized water or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water according to the manufactur-
er's instruction.

Using of coolant with includes more than 50 % (freezing protection down to ±35C (±31F)) or 60 %
(freezing protection down to ±50C (±58F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times by hand.

If the coolant level gets lower, pour coolant.
(b) Reinstall the radiator cap.
(c) Pour engine coolant into the reservoir tank until it reaches full line.

16±32
±
COOLING ENGINE COOLANT(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
2.ADD ENGINE COOLANT
(a)Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD6.0 (6.3, 5.3)
M/TRHD6.1 (6.4, 5.4)
A/TLHD6.3 (6.7, 5.5)
A/TRHD6.4 (6.8, 5.6)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's directions.

Using of coolant with includes more than 50 % (freezing protection down to ±\
35 C (±31 F)) or 60 %
(freezing protection down to ±50 C (±58 F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times with hard.

If the coolant level gets lower, pour coolant.
(b)Reinstall the radiator cap.
(c)Pour engine coolant into the reservoir tank until it reaches full line.
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times with hard during \
the warming up.
(e)Stop the engine and wait until the coolant temp. Gets cold. Then remove the radiator cap to check the coolant level.
HINT:

If the level gets lower, perform the procedures above again.

If the level does not gets lower, adjust the reservoir tank coolant level.
3.CHECK FOR ENGINE COOLANT LEAKS(See page 16±25)