battery replacement TOYOTA AVENSIS 2005 Service User Guide

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.

4011N±01
D28034
Claw
Shift Lock Release Link
D28033
Shift Lever Plate
C88567
40±74
±
AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT PARKING LOCK CABLE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
FLOOR SHIFT PARKING LOCK CABLE ASSY
REPLACEMENT
1.PRECAUTION (See page 60±29)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3.REMOVE INSTRUMENT PANEL HOLE COVER (See page 71±11)
4.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±29)
5.REMOVE INSTRUMENT PANEL UNDER COVER SUB±ASSY NO.1 (See page 71±11)
6.REMOVE STEERING COLUMN COVER LWR (See page 50±9)
7.REMOVE STEERING COLUMN COVER (See page 50±9)
8.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
9.REMOVE CONSOLE PANEL UPPER ASSY (See page 71±11)
10.REMOVE CONSOLE REAR END PANEL (See page 71±11)
11.REMOVE CONSOLE BOX ASSY RR (See page 71±11) 12. REMOVE FLOOR SHIFT PARKING LOCK CABLEASSY
(a) Push the claw and disconnect the parking lock cable assy from the shift lock release link.
(b) Using a screw driver, disconnect the parking lock cable assy from the shift lever plate.
(c) Disconnect the cable clamp.
(d) Turn the ignition switch to ACC or ON.

410DY±01
D26902
D26903
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±33
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.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 WHEELS
7. REMOVE ENGINE UNDER COVER RH
8. REMOVE ENGINE UNDER COVER LH
9. DRAIN TRANSAXLE OIL
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18.REMOVE AIR TUBE NO.1 (See page 14±286)
19. SEPARATE RADIATOR RESERVE TANK ASSY
(a) Remove the 2 bolts, separate the radiator reserve tankassy.
20. REMOVE STARTER ASSY
(a) Remove the nut, disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.

410DU±01
D30480
D30081
41±24
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.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 WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER SUB±ASSY NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. 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.

4105X±04
D30480

D30691
D30482
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±15
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.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 WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE CYLINDER HEAD COVER NO.2
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19. DISCONNECT WIRE HARNESS
(a) Remove the 3 bolts, disconnect the wire harness clamps.
(b) Remove the bolt, disconnect the ground cable.

5006Z±01
50±20
±
STEERING COLUMN POWER STEERING ECU ASSY
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING ECU ASSY
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.1 (See page 71±11)
4.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
5.REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 71±11)
6.REMOVE STEERING COLUMN COVER LWR (See page 50±9)
7. REMOVE STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY (See page 50±9)
8.REMOVE COMBINATION METER ASSY (See page 71±11)
9.REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (See page 71±11)
10.REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2(See page 71±11)
11.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
12.REMOVE FRONT PILLAR GARNISH LH (See page 71±11)
13.REMOVE FRONT PILLAR GARNISH RH (See page 71±11)
14.DISCONNECT PASSENGER AIRBAG CONNECTOR(See page 71±11)
15. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG
ASSY (See page 71±11)
16. REMOVE POWER STEERING ECU ASSY
NOTICE:
Thoroughly check the procedures for removing and instal-
ling the power steering ECU assy when replacing it. Do the
same for the removing and installing the steering column
assy.
(a) Mark the clamp position on the torque sensor wire har-ness in order to reinstall the wire harness as shown in the
illustration.
(b) Disconnect the torque sensor wire harness from the clamp.
NOTICE:
In case the clamp will be reused, pay attention so as not to
damage it.
(c) Disconnect the 4 connectors.
(d) LHD: (1) Remove the 2 bolts,screw and power steering ECUassy.
(e) RHD: (1) Remove the 2 bolts,2 screw and power steeringECU assy.

4206G±01
D30813
(a)
(a) (b)(b)
(a)
(b)
D30813
(a)
(a) (b)(b)
(a)
(b)
D26852
SST(s)
42±22
±
CLUTCH CLUTCH ACCUMULATOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE BATTERY
2.REMOVE AIR TUBE NO.1 (See page 14±286) 3. REMOVE CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), disconnect the flexible hose tube.SST 09023±00100
HINT:
Use a container to catch the fluid.
(b) Remove a bolt, 2 nuts and clutch accumulator assy.
4. INSTALL CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), connect the 2 flexible hose tubes to the clutch accumulator assy.
SST 09023±00100
(b) Install the clutch accumulator assy with the 2 nuts and a
bolt.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
(c) Using SST(s), tighten the flexible hose tube. SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
5.INSTALL AIR TUBE NO.1 (See page 14±286)
6. INSTALL BATTERY
7. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the brake fluid and bleed clutch syst\
em. Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
8. CHECK CLUTCH FLUID LEAKAGE

600JY±01
H42642
H42643
H42644
Hook
Airbag DoorHook
Front
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±29
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
4. DISCONNECT PASSENGER AIRBAG CONNECTOR
(a) Remove the passenger airbag connector clip.
(b) Disconnect the passenger airbag connector.
5. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
6. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSY
(a) Remove the 2 screws.
(b) Release the rear side wall of the airbag door from the hook by slightly deflecting it and roll the instrument panel
passenger airbag assy forward.
(c) Release the front side wall of the airbag door from the oth-
er hook and remove the instrument panel passenger air-
bag assy.
7. INSTALL INSTRUMENT PANEL PASSENGER AIR BAG ASSY
8.INSPECT INSTRUMENT PANEL PASSENGER AIR BAG ASSY (See page 60±11)
9. INSTALL INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
10.INSPECT SRS WARNING LIGHT (See page 05±1184)

6009S±04
H42634
H42636 Claw
60±26
±
SUPPLEMENTAL RESTRAINT SYSTEM SPIRAL CABLE SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
SPIRAL CABLE SUB±ASSY
REPLACEMENT
HINT:
COMPONENTS: See page 60±16
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4.REMOVE HORN BUTTON ASSY (See page 60±17)
5.REMOVE STEERING WHEEL ASSY (See page 50±9) SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±\
05021)
6.REMOVE INSTRUMENT PANEL HOLE COVER (See page 60±54)
7.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
8. REMOVE STEERING COLUMN COVER SUB±ASSYLOWER
(a) Remove the 3 screws and the steering column cover sub± assy lower.
9. REMOVE STEERING COLUMN COVER
W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Remove the steering column cover w/instrument cluster finish panel assy.
10. REMOVE SPIRAL CABLE SUB±ASSY
(a) Disconnect the airbag connector and the connector from the spiral cable sub±assy.
(b) Disengage the 3 claws and remove the spiral cable sub±
assy.
11.INSPECT SPIRAL CABLE SUB±ASSY (See page 60±11)
(a) If the following condition is identified, replace the spiral cable sub±\
assy with a new one. Condition:
Scratches or cracks on the connector
Cracks, dents or chips in the spiral cable sub±assy
12. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
(a) Check that the front wheels are facing straight ahead.

6009P±04
H42622
H43002
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
60±17
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. REMOVE HORN BUTTON ASSY
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench (T30), loosen the 2 torxscrews until the groove along the screw circumference
catches on the screw case.
(c) Pull out the horn button assy from the steering wheel assy and support the horn button assy with one hand as shown
in the illustration.
NOTICE:
When removing the horn button assy, do not pull the airbag
wire harness.
(d) Using a screwdriver, disconnect the airbag connectors.
(e) Disconnect the horn connector.
(f) Remove the horn button assy.