manual transmission TOYOTA AVENSIS 2005 Service User Guide

02±10
± PREPARATIONENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
09249±63010Torque Wrench AdaptorFAN AND GENERATOR V
BELT(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
FAN AND GENERATOR V
BELT(1AZ±FSE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
09268±21010Fuel Hose PullerCYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
09268±46021Nozzle Holder Retaining Nut
WrenchPARTIAL ENGINE ASSY(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
09301±00210Clutch Guide ToolPARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09301±00220Clutch Guide ToolENGINE REAR OIL SEAL(1CD±FTV)
09316±60011Transmission & Transfer Bearing
ReplacerCRANKSHAFT SEAL(1CD±FTV)
(09316±00011)Replacer PipeCRANKSHAFT SEAL(1CD±FTV)
09330±00021Companion Flange Holding ToolPARTIAL ENGINE ASSY(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
ENGINE REAR OIL SEAL(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
ENGINE REAR OIL SEAL(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
ENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)

022KY±01
02±40
± PREPARATIONMANUAL TRANSMISSION/TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSMISSION/TRANSAXLE
PREPARATION
SST
09023±00100Union Nut Wrench 10 mmMANUAL TRANSAXLE
ASSY(1CD±FTV)
09023±12700Union Nut Wrench 17mmMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
09308±00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09520±01010Drive Shaft Remover AttachmentMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09520±24010Differential Side Gear Shaft
PullerMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
(09520±32040)Shocker SetMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09554±14010Differential Oil Seal ReplacerFRONT DIFFERENTIAL OIL
SEAL(C50/C250)
09608±10010Steering Knuckle Oil Seal
ReplacerFRONT DIFFERENTIAL OIL
SEAL(E354/E357)

± PREPARATIONMANUAL TRANSMISSION/TRANSAXLE
02±41
AVENSIS REPAIR MANUAL (RM1018E)
09608±32010Steering Knuckle Oil Seal
ReplacerFRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09628±62011Boll Joint PullerMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09670±00010Front Crossmember Guide ToolMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
09930±00010Drive Shaft Nut ChiselMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09950±70010Handle SetFRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
(09951±07200)Handle 200FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
Recomended Tools
09011±12301Socket Wrench 30 mmMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)

02±42
± PREPARATIONMANUAL TRANSMISSION/TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
Equipment
Torque wrench
Hexagon wrench (6 mm)
Lubricant
ItemCapacityClassification
C50, C250
Manual Transaxle oil
(w/ Differential oil)
1.9 litters (2.0 US qts, 1.7 Imp. qts)API GL±4 or GL±5
SAE 75W±90
E354, E357
Manual Transaxle oil
(w/ Differential oil)
2.5 litters (2.6 US qts, 2.2 Imp. qts)API GL±4 or GL±5
SAE 75W±90

022L4±02
02±36
± PREPARATIONAUTOMATIC TRANSMISSION / TRANS
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
07110±58060Air Conditioner Service Tool SetTRANSMISSION CONTROL CABLE
ASSY
(07117±58060)Refrigerant Drain Service ValveTRANSMISSION CONTROL CABLE
ASSY
(07117±58070)T±JointTRANSMISSION CONTROL CABLE
ASSY
(07117±58080)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±58090)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±78050)Refrigerant Charging GaugeTRANSMISSION CONTROL CABLE
ASSY
(07117±88060)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88070)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88080)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
09023±12700Union Nut Wrench 17mmAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09308±00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09316±60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U241E)

± PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02±37
AVENSIS REPAIR MANUAL (RM1018E)
(09316±00011)Replacer PipeFRONT DIFFERENTIAL OIL
SEAL(U241E)
09350±32014TOYOTA Automatic Transmission
Tool SetTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
(09351±32010)One±way Clutch Test ToolTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
(09351±32020)Stator StopperTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09520±01010Drive Shaft Remover AttachmentAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09520±24010Differential Side Gear Shaft
PullerAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
(09520±32040)Shocker SetAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09554±14010Differential Oil Seal ReplacerFRONT DIFFERENTIAL OIL
SEAL(U341E)
09628±62011Boll Joint PullerAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09649±17010Steering Knuckle ToolFRONT DIFFERENTIAL OIL
SEAL(U241E)
09726±27012Front Suspension Arm Bushing
Remover & ReplacerFRONT DIFFERENTIAL OIL
SEAL(U341E)

02±38
± PREPARATIONAUTOMATIC TRANSMISSION / TRANS
AVENSIS REPAIR MANUAL (RM1018E)
(09726±02041)ReplacerFRONT DIFFERENTIAL OIL
SEAL(U341E)
09930±00010Drive Shaft Nut ChiselAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09950±70010Handle SetFRONT DIFFERENTIAL OIL
SEAL(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
(09951±07150)Handle 150FRONT DIFFERENTIAL OIL
SEAL(U241E)
(09951±07200)Handle 200FRONT DIFFERENTIAL OIL
SEAL(U341E)
Recomended Tools
09011±12301Socket Wrench 30 mmAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09040±00011Hexagon Wrench SetAUTOMATIC TRANSAXLE
ASSY(U241E)
TRANSMISSION WIRE(U241E)
TRANSMISSION VALVE BODY
ASSY(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
(09043±20100)Socket Hexagon Wrench 10AUTOMATIC TRANSAXLE
ASSY(U241E)
TRANSMISSION WIRE(U241E)
TRANSMISSION VALVE BODY
ASSY(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
TRANSMISSION VALVE BODY
ASSY(U341E)
TRANSMISSION WIRE(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09042±00010Torx Socket T30TRANSMISSION CONTROL CABLE
ASSY

± PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02±39
AVENSIS REPAIR MANUAL (RM1018E)
09090±04020Engine Sling DeviceAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
95416±00140Gas Leak Detector
(Halogen Leak Detector)
(DENSO Part No.)TRANSMISSION CONTROL CABLE
ASSY
09216±00021Belt Tension GaugeAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
SSM
08833±00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalentTRANSMISSION WIRE(U241E)
TRANSMISSION VALVE BODY
ASSY(U241E)
Equipment
Straight edgeAutomatic transaxle assy
Torque wrench
Vernier calipersAutomatic transaxle assy
Dial indicator with magnetic baseTorque converter and drive plate
Slide calipersAutomatic transaxle assy
Chain blockAutomatic transaxle assy
Lubricant
U341E
Automatic transaxle fluid
Dry fill
Drain and refill
6.9 liter (7.7 USqts, 6.4 lmp.qts)
3.0 liter (3.2 USqts, 2.6 lmp.qts)ATF type T±IV
U241F
Automatic transaxle fluid
Dry fill
Drain and refill
8.6 liter (9.0 USqts, 7.6 lmp.qts)
3.5 liter (3.7 USqts, 3.1 lmp.qts)ATF type T±IV

031DZ±02
03±6
± SERVICE SPECIFICATIONSENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle position sensor x Throttle body assy2.02018 in.
lbf
ISC valve x Throttle body assy3.73833 in.
lbf
Accelerator control cable bracket x Throttle body assy1313310
Throttle body assy x Intake manifold3030622
Throttle body bracket x Cylinder block sub±assy (1ZZ±FE)3030622
Manifold stay No. 2 x Throttle body assy (M/T)1313310
Accelerator control cable assy x Accelerator control cable bracket131299
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold3030622
Accelerator control cable assy x Throttle body assy131299
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
Intake manifold x Cylinder head sub±assy3030622
Variable resister x Body (Leaded gasoline (Steering position LHD))5.05144 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold9.09280 in.
lbf
Throttle body bracket x Throttle body assy2121015
Throttle body bracket x Cylinder head sub±assy2121015
Ground terminal x Throttle body bracket8.48674 in.
lbf
Wire harness protector x Throttle body bracket8.48674 in.
lbf
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Accelerator pedal x Body5.45548 in.
lbf
Knock control sensor x Cylinder block2020415
Engine cover bracket x Cylinder head3838828
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Intake shutter assy x Intake air connector2121415
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Air tube No. 2 x Transmission2525518
Air tube No. 1 x Air tube No. 22525518
Camshaft position sensor x Camshaft oil seal retainer8.89079 in.
lbf
Return tube sub±assy x Engine hanger No. 19.09280 in.
lbf
Crankshaft position sensor x Oil pump assy8.89079 in.
lbf
ECM x Body5.55649 in.
lbf

030AA±10
03±50
± SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
U341E
Part TightenedN
mkgf
cmft
lbf
Park/neutral position switch x Transaxle Bolt
Nut5.4
6.955
7048 in.
lbf
61 in.
lbf
Control shaft lever x Park/neutral position switch131309
Battery carrier x Body1313210
Engine hanger x Engine3838728
Drain plug x Oil pan4950036
Transaxle x Engine Bolt A:
Bolt B:
Bolt C:64
46
23650
470
23547
34
17
Torque converter clutch x Drive plate2828520
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket FR x Transaxle6465347
Center member x Body Bolt A:4545933
Center member x Suspension member Bolt B:
BoltC:96
52979
53071
38
Engine mounting insulator RR x Engine mounting bracket RR8788764
Engine mounting insulator RR x Suspension member5253038
Engine mounting insulator FR x Engine mounting bracket FR5253038
Engine mounting bracket LH x Transaxle6465347
Engine mounting insulator LH x Body Bolt A:
Nut B:52
80530
81538
59
Starter x Transaxle3737727
Starter wire x Starter9.810087 in.
lbf
Froor panel brace x Body3030222
Oil filler tube x Transaxle Bolt A:121229
Oil cooler tube clamp x Oil filler tube Bolt B:5.55649 in.
lbf
Oil cooler outlet tube x Transaxle3535725
Oil cooler inlet tube x Transaxle3535725
Wire harness clamp bracket x Transaxle121229
Wire harness x Transaxle Bolt A:
Bolt B:5
2651
26544 in.
lbf
19
Control cable bracket x Transaxle121229
Control cable support x Transaxle121229
Air cleaner assy x Body7.07162 in.
lbf
Cylinder head cover No. 2 x Engine7.07162 in.
lbf
Speed sensor x Transaxle5.45548 in.
lbf
Transmission wire x Transaxle5.45548
Solenoid valve x Valve body Bolt A:
Bolt B:11
1111 0
11 08
8
Valve body x Transaxle1111 08
ATF temperature sensor x Valve body1111 08
Oil strainer x Valve body1111 08
Oil pan x Transaxle7.88069 in.
lbf
Floor shift assembly x Body121229
Control cable x Control shaft lever121229