TOYOTA AVENSIS 2005 Service Repair Manual

F45057
w/o VSC:
w/ VSC:
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
A
To
Master
Cylinder
FrontTo Master
Cylinder
Rear
To Rear
Wheel RH
To Front Wheel LHTo Front Wheel RH
To Rear
Wheel LH
AA
AA
BB
C80806
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±31
AVENSIS REPAIR MANUAL (RM1018E)
(e) w/o VSC:
Using SST, connect the 6 brake tubes to the brake actua-
tor, as shown in the illustration.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(f) w/ VSC: Using SST, connect the 6 brake tubes to the brake actua-
tor as shown in the illustration.
SST 09023±00100, 09023±38400
Torque:
A: 15 N
m (155 kgf
cm, 11 ft
lbf)
B: 29 N
m (296 kgf
cm, 21 ft
lbf)
(g) Install the brake tube clamps with the 2 bolts. Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
20. INSTALL FRONT WHEEL RH
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
22.INSTALL IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
23.INSTALL INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
24.INSTALL CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
25.INSTALL TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)

32±32
±
BRAKE BRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
26. INSTALL ENGINE COVER NO.1
27.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
28.INSTALL CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
29.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
30.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
31.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100, 09023±00100
(b) w/ VSC: SST 09023±00100, 09023±00100
32.BLEED BRAKE LINE (See page 32±4)
33.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
34.CHECK PEDAL FREE PLAY (See page 32±6)
35.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
36.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
37.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (M/T TRANSAXLE) (See page 42±2)
38.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
39. CHECK BRAKE FLUID LEAKAGE
40. CHECK CLUTCH FLUID LEAKAGE (M/T TRANSAXLE)

400DA±02



D30339
Neutral
Basic Line
Groove
Neutral
Basic Line
GrooveU241E:
U341E: 40±8
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P posi-
tion and it does not start in other position.
(c) Check that the back±up light is on and the reverse warning buzzer sounds only when the shift lever
is set in R position and these do not function in other position.
If a failure is found, check the park/neutral position switch for continuity.
2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSY
(a) Loosen the 2 bolts of park/neutral position switch and set
the shift lever to the N position.
(b) Align the groove and neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
(d) After adjustment, perform the inspection described in
step 1.

4011W±01



D30337
U241E:
U341E:
C81535
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
40±3
AVENSIS REPAIR MANUAL (RM1018E)
PARK/NEUTRAL POSITION SWITCH ASSY (ATM)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. 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 separate the control cable from the
control cable bracket.


D30338
U241E:
U341E:
C99454
D31059
D30919N 40±4
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Disconnect the park/neutral position switch connector.
(b) Remove the nut, washer and control shaft lever.
(c) Pry out the lock plate and remove the manual valve shaft
nut and lock plate.
(d) Remove the 2 bolts and pull out the park/neutral position
switch.
4. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) U241E:
(1) Install the park/neutral position switch to the manual
valve shaft.
(2) Temporarily install the 2 bolts.
(3) Place a new lock plate and tighten the nut.
Torque: 6.9 N
m (70 kgf
cm, 61 in.
lbf)
(4) Temporarily install the control shaft lever.
(5) Turn the lever counterclockwise until it stops, then
turn it clockwise 2 notches.
(6) Remove the control shaft lever.

C99456
GrooveNeutral
Basic Line
C99457
C99458
C62665

D31060
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
40±5
AVENSIS REPAIR MANUAL (RM1018E)
(7) Align the groove with the neutral basic line.
(8) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
(9) Using a screwdriver, stake the nut with the lock
plate.
(10) Install the control shaft lever, washer and nut.
Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(11) Connect the park/neutral position switch connector.
(b) U341E:
(1) Install the park/neutral position switch to the manual
valve shaft.
(2) Temporarily install the 2 bolts.
(3) Place a new lock plate and tighten the nut.
Torque: 6.9 N
m (70 kgf
cm, 61 in.
lbf)
(4) Temporarily install the control shaft lever.

C82031
N

G25654
Groove
Neutral
Basic Line
C62669
C82032
C81535
40±6
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Turn the lever counterclockwise until it stops, then
turn it clockwise 2 notches.
(6) Remove the control shaft lever.
(7) Align the groove with the Gneutral basic line.
(8) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in. lbf)
(9) Using a screwdriver, stake the nut with the lock
plate.
(10) Install the control shaft lever, washer and nut.
Torque: 13 Nm (130 kgfcm, 9 ftlbf)
(11) Connect the park/neutral position switch connector.
5. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Install the control cable and clip to the control cable brack-
et.




D30337
U241E:
U341E:
±
AUTOMATIC TRANSMISSION / TRANS PARK/NEUTRAL POSITION SWITCH ASSY(ATM)
40±7
AVENSIS REPAIR MANUAL (RM1018E)
(b)Temporarily install the control cable to the control shaft le-
ver with the nut.
6.ADJUST SHIFT LEVER POSITION (See page 40±69)
7.INSPECT SHIFT LEVER POSITION (See page 40±69)
8.INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 40±8)

400D7±02
D25120
OK if hot
Add if hot 40±2
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE FLUID (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSAXLE FLUID (ATM)
ON±VEHICLE INSPECTION
1. CHECK THE FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at the nor-
mal operating temperature.
Fluid temperature: 70 ± 80
C (158 ± 176
F)
(a) Park the vehicle on a level surface and set the parking
brake.
(b) With the engine idling and the brake pedal depressed,
shift the shift lever into all position from P to L position and
return to P position.
(c) Pull out the dipstick and wipe it clean.
(d) Push it back fully into the pipe.
(e) Pull it out and check that the fluid level is in the HOT posi-
tion.
If there are leaks, it is necessary to repair or replace O±rings,
FIPGs, oil seals, plugs or other parts.

400D8±02
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (ATM)
40±1
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSAXLE ASSY (ATM)
PRECAUTION
1. The automatic transaxle is composed of highly precision±finished parts which need careful in-
spection before reassembly because even a small nick could cause fluid leakage or affect the
performance. The instructions here are organized in order to work on only one component
group at a time. This will help avoid confusion comes from the similar±looking part of the differ-
ent sub±assemblies being on your workbench at the same time. Inspect and repair the compo-
nent groups from the converter housing side. Complete the inspection, repair and reassembly
before proceeding to the next component group. If a defect is found in a certain component
group during reassembly, inspect and repair this group immediately. If a component group can-
not be assembled because the necessary parts are being ordered, be sure to keep all the parts
of the group in a separate container while proceeding with disassembly, inspection, repair and
reassembly of the other component groups.
Recommended ATF: T±IV
2. All the disassembled parts should be washed clean and any fluid passages and holes should
be blown through with compressed air.
3. Dry all parts with compressed air. Never use shop rags to dry them.
4. Be careful of ATF or kerosene not to be squirted over your face when using compressed air.
5. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs,
and reassembly.
7. When disassembling the valve body, be sure to match each valve together with the correspond-
ing spring.
8. New discs for the replacement of the brakes and clutches must be soaked in ATF for at least
15 minutes before reassembly.
9. All the oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
10. Replace all the gaskets and rubber O±rings.
11. Do not apply adhesive cements to the gaskets and similar parts.
12. Make sure that the ends of the snap ring are not aligned with one of the cutouts and are installed
in the groove correctly.
13. If a worn bushing is to be replaced, the sub±assembly containing the bushing must also be re-
placed.
14. Check the thrust bearings and races for wear or damage. Replace them as necessary.
15. Use petroleum jelly to keep the parts in place.
16. When working with FIPG material, you must follow the procedure below.

Remove all the old packing (FIPG) material from the gasket surface using a razor blade and a
gasket scraper.

Thoroughly clean all the components to remove all the loose material.

Clean both the sealing surfaces with non±residue solvent.

Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) ma-
terial must be removed and reapplied.