hood open TOYOTA AVENSIS 2005 Service User Guide
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2005, Model line: AVENSIS, Model: TOYOTA AVENSIS 2005Pages: 5135, PDF Size: 95.28 MB
Page 2778 of 5135
410DV±01
D30475
13 (133, 10)Hood Sub±assy
Radiator Reserve Tank Assy
Engine Cover No.1
5.0 (51, 44 in.lbf)
7.0 (71, 62 in.lbf)
Air Cleaner Assy
Battery Clamp
Sub±assy
3.5 (36, 31 in.lbf)
Battery
Battery Tray
Clip
Clip
Clip
Floor Shift Transmission
Control Cable Assy
Starter Assy
Starter Connector
Ground Cable
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)
Manual Transmission
Case Protector
64 (653, 47)
40 (408, 30)
20 (200, 14)
8.0 (82, 71 in.lbf)
40 (408, 30)
64 (653, 47)
Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
12 (120, 9)
5.0 (51, 44 in.lbf)
64 (653, 47)
Manual Transaxle Assy
13 (133, 10)
37 (380, 27)
46 (469, 34)
13 (130, 9)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.lbf)
8.0 (82, 71 in.lbf)
6.0 (61, 53 in.lbf)
52 (530, 38)
25 (255, 18)
Air Tube No.1
25 (255, 18)
Engine Room Cover Side
Radiator Support
Opening Cover
Clip
13 (131, 9)
12 (120, 9)
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1CD±FTV)
41±31
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1CD±FTV)
COMPONENTS
Page 2780 of 5135
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.
Page 2786 of 5135
D30080
41±30
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts. Torque: 13 N m (131 kgf cm, 9 ft lbf)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N m (51 kgf cm, 44 in. lbf)
Nut: 3.5 N m (36 kgf cm, 31 in. lbf)
59. INSTALL AIR CLEANER ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
60. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUB±ASSY Torque: 13 N m (132 kgf cm, 10 ft lbf)
64.INSPECT HOOD SUB±ASSY (See page 75±2)
65.ADJUST HOOD SUB±ASSY (See page 75±2)
66.ADD TRANSAXLE OIL (See page 41±5)
67.INSPECT TRANSAXLE OIL (See page 41±2)
68. INSTALL FRONT WHEELS
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
69.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
70.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page)See page 50±9)
71.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
72.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76.BLEED POWER STEERING FLUID (See page 51±4)
77.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
78.INSPECT FLUID LEAK (See page 51±4)
79.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
83.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
Page 2787 of 5135
410DT±01
D30082
13 (133, 10)Hood Sub±assy
Engine Cover Sub±assy No.1
Air Cleaner Assy
Battery
Battery Tray
Clip
Clip
Clip
Starter Assy
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)
Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
12 (120, 9)
Manual Transaxle Assy
46 (469, 34)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.lbf)
Engine Room Cover Side
Radiator Support Opening Cover
44 (449, 32)
44 (449, 32)
Clutch Release Cylinder Assy
Starter
Connector
37 (380, 27)
13 (130, 9)
46 (469, 34)
8.4 (85, 74 in.lbf)
46 (469, 34)
Transmission Control Cable Assy
Battery Clamp Sub±assy
5.0 (51, 44 in.lbf)
9.0 (92, 80 in.lbf)
Back±up Lamp Switch Connector
5.0 (51, 44 in.lbf)
Clip
26 (260, 19)
40 (410, 30)
64 (653, 47)
52 (530, 38)
13 (131, 9)
41±22
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS
Page 2789 of 5135
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.
Page 2795 of 5135
D30480
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±21
AVENSIS REPAIR MANUAL (RM1018E)
51. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts.
Torque: 13 N m (131 kgf cm, 9 ft lbf)
52. INSTALL BATTERY TRAY
53. INSTALL BATTERY
54. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N m (51 kgf cm, 44 in. lbf)
Nut: 3.5 N m (36 kgf cm, 31 in. lbf)
55. INSTALL AIR CLEANER ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
56. INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
57. INSTALL ENGINE ROOM COVER SIDE
58. INSTALL RADIATOR SUPPORT OPENING COVER
59. INSTALL HOOD SUB±ASSY Torque: 13 N m (133 kgf cm, 10 ft lbf)
60.INSPECT HOOD SUB±ASSY (See page 75±2)
61.ADJUST HOOD SUB±ASSY (See page 75±2)
62.ADD TRANSAXLE OIL (See page 41±3)
63.INSPECT TRANSAXLE OIL (See page 41±2)
64. INSTALL FRONT WHEELS
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
65.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
66.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
67.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
68.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
69. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
70. STEERING WHEEL CENTER POINT
71.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
72. INSTALL ENGINE UNDER COVER LH
73. INSTALL ENGINE UNDER COVER RH
74. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
75.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
Page 2796 of 5135
410DS±01
D30478
Battery Clamp Sub±assy
Battery Tray
Charcoal Canister Assy Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2
Starter AssyBack±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
ClipClip
37 (380, 27)
Starter Connector
Transverse Engine
Engine Mounting Insulator
52 (530, 38)
52 (530, 38)
Ground Cable Gasket
7.0 (71, 62 in.lbf)
Filler Plug
37 (380, 27)
23 (230, 17)
47 (479, 35)
N´m (kgf´cm, ft´lbf) : Specified torque
19 (195, 14)
13 (130, 9)
64 (653, 47)
64 (653, 47)
5.0 (51, 44 in.lbf)
Non±reusable part
5.0 (51, 44 in.lbf)
14 (141, 10)
13 (133, 10)
13 (131, 9)
5.0 (51, 44 in.lbf)
26 (260, 19)
25 (255, 18)
80 (816, 59)
26 (260, 19)
23 (230, 17)
Engine Room Cover Side
Radiator Support Opening Cover
40 (410, 30)
39 (400, 29)
Manual Transaxle Assy
64 (653, 47)
Battery
Clutch Release Cylinder Assy
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
Page 2908 of 5135
± 50 g (± 1.76 oz.)
I37057
0.1 (1.0)0.4 (4.0)
0.3 (3.0)
0.2 (2.0)MPa (kgf/cm
2) Pressure on low pressure side
Outside temperature 0
C (F) 15 (59) 20 (68) 30 (86)25 (77) 35 (95)
0 g (0 oz.)
(Standard)
+ 50 g (+ 1.76 oz.)
± HEATER & AIR CONDITIONERREFRIGERANT
55±31
AVENSIS REPAIR MANUAL (RM1018E)
3. w/ Hot gas heater:
INSPECT REFRIGERANT VOLUME
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the the manifold gauge pres-
sure when these conditions are established.
Test conditions:
Engine is at idle.
Blower speed control switch is at ºHIº.
Temperature control dial is at ºMAX. COOLº.
Engine has been warmed up.
All doors are fully open.
Hood is fully open.
Air inlet mode selector damper is at RECIRE.
Air outlet damper is at FACE.
Outside temperature is 15 ± 35 C (59± 95
F).
(b) Check refrigerant volume according to the graph below.
RangeAmount of refrigerantCorrective actions
Except range belowInsufficient or excessive
Supply refrigerant until low
pressure become within
the standard 50 g
(1.76 oz.), or remove
refrigerant and then sup-
ply proper amount of re-
frigerant
Standard 50 g
(1.76 oz.)Proper±
Page 3000 of 5135
I35337
I35336
I35339
I35340
55±94
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE DISCHARGE TUBE SUB±ASSY (W/ HOT GAS HEATER)
(a) Remove the 2 bolts and disconnect the discharge tube
sub±assy from the w/ receiver condenser assy.
(b) Remove 2 O±rings from the discharge tube sub±assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
6. REMOVE LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV) STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the liquid tube sub±assy B from w/ receiver condenser assy.
(b) Remove the O±ring from the liquid tube sub±assy B.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
7. REMOVE HOOD LOCK ASSY
(a) Remove the 3 bolts and the hood lock assy.
8.REMOVE HIGH PITCHED HORN ASSY (See page 69±5)
9.REMOVE LOW PITCHED HORN ASSY (See page 69±4) 10. REMOVE HOOD LOCK SUPPORT BRACE
(a) Remove the 5 bolts and the hood lock support brace.
Page 3228 of 5135
B660325 Clips
71±18
±
INSTRUMENT PANEL/METER INSTRUMENT PANEL SUB±ASSY LOWER
AVENSIS REPAIR MANUAL (RM1018E)
36.REMOVE INSTRUMENT PANEL LOWER ASSY
(a)Disconnect the hood lock control cable.
(b)Using a clip remover, remove the 2 clips.
(c)Remove the 2 bolts 7 screws
(d)Disengage the wire harness 5 clamps.
(e)Remove the instrument panel lower assy.
37.REMOVE OUTER MIRROR SWITCH ASSY W/BEZEL
38.REMOVE FUSE BOX OPENING COVER
39.REMOVE GLOVE BOX LAMP ASSY
40.REMOVE INSTRUMENT PANEL BRACKET SUB±ASSY CENTER
(a)Remove the screw
41.REMOVE INSTRUMENT PANEL SUB±ASSY LOWER
42.INSTALL INSTRUMENT PANEL AIR BAG ASSY (See page 60±29)