TOYOTA AVENSIS 2005 Service Repair Manual

F42641
F42642
F45427
F45426
32±66
±
BRAKE STEERING SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
11. INSTALL STEERING SENSOR
(a) Install the steering sensor adapter to the column shaft.
HINT:
At that time, the projection of the steering sensor adapter
should be fit in the hole on the steering column shaft.
(b) Install the steering sensor to the column shaft.
HINT:

At that time, the pick of the steering sensor should be fit
to the pick of the steering sensor adapter.

After installation, make sure the steering sensor is fixed
securely in the steering sensor adapter.
(c) Place the steering column assy on the V±blocks and rub- ber stick.
(d) Install the 2 new tilt steering support collar No.1 to the steering column assy.
(e) Using a extension bar and hammer, install the steering column bracket spacer to the steering column assy.
NOTICE:

During this procedure, do not apply the strong shock
to the steering sensor.

Do not apply any grease or oil on the pin.
12.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
13.INSTALL STEERING COLUMN ASSY (See page 50±9)
14.INSTALL SPIRAL CABLE SUB±ASSY (See page 60±26)
15. INSTALL STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY (See page 50±9)
16.INSTALL STEERING COLUMN COVER LWR (See page 50±9)
17.INSTALL STEERING WHEEL ASSY (See page 50±9)
18. INSPECT STEERING WHEEL CENTER POINT
19.INSTALL HORN BUTTON ASSY (See page 60±17)

±
BRAKE STEERING SENSOR
32±67
AVENSIS REPAIR MANUAL (RM1018E)
20.CONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
21.INSPECT SRS WARNING LIGHT (See page 05±1184)
22.INSPECT ABS WARNING LIGHT AND VSC WARNING LIGHT (See page 05±756)

320GM±02
G23169
G23170
G23171
G23170
±
BRAKE YAWRATE SENSOR
32±63
AVENSIS REPAIR MANUAL (RM1018E)
YAWRATE SENSOR
REPLACEMENT
NOTICE:

Don't use the dropped or damaged yawrate sensor.

Free from the foreing matters between yawrate sensor braket and body.

Make sure the sensor direction.
1.REMOVE FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
2. REMOVE YAWRATE SENSOR BRACKET
(a) Remove the bolt and upper part of the yawrate sensorbracket.
3. REMOVE YAWRATE SENSOR
(a) Disconnect the yawrate sensor connector from the yaw- rate sensor.
(b) Remove the 2 bolts and the yawrate sensor with the yaw- rate sensor bracket from the body.
(c) Remove the 2 nuts and yawrate sensor from the yawrate sensor bracket.
4. INSTALL YAWRATE SENSOR
(a) Install the 2 nuts and yawrate sensor to the yawrate sen- sor bracket.
Torque: 6 N
m (61 ft
lbf, 53 in.
lbf)
(b) Install the 2 bolts and the yawrate sensor with the yawrate sensor bracket to the body.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
(c) Connect the yawrate sensor connector to the yawrate sensor.

G23169
32±64
±
BRAKE YAWRATE SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL YAWRATE SENSOR BRACKET
(a) Install the bolt and upper part og the yawrate sensor bracket.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
6.INSTALL FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
7.PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (See page 05±756)

400DD±02
C83111
AT0103
D25591
C50009
40±52
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION WIRE (U241E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all of the oil
pan bolts, and carefully remove the oil pan assembly. Dis-
card the gasket.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Remove the magnets and use them to collect any
steel chips. Look at the chips and particles in the oil
pan and on the magnet carefully to see the type of
wear which might be found in the tranaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non±magnetic): bearing wear
4. SEPARATE TRANSMISSION WIRE
(a) Disconnect the 5 solenoid valve connectors.
(b) Remove the bolt and lock plate, and separate the ATF
temperature sensor.
5. REMOVE TRANSMISSION WIRE
(a) Disconnect the transmission wire connector.
(b) Remove the bolt and transmission wire.

D03636
C50009
D25591
D25674
Magnet
C83111
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U241E)
40±53
AVENSIS REPAIR MANUAL (RM1018E)
6. INSTALL TRANSMISSION WIRE
(a) Coat an O±ring of the transmission wire connector with
AT F.
(b) Install the transmission wire.
(c) Install the bolt.
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
7. CONNECT TRANSMISSION WIRE
(a) Coat an O±ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor with the lock plate and
bolt.
Torque: 6.6 N
m (67 kgf
cm, 58 in.
lbf)
(c) Connect the 5 solenoid valve connectors.
8. INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply the seal packing or equivalent to the 18 bolts.
Seal packing:
THREE BOND 1344 or equivalent
(c) Install a new gasket and the oil pan to the transaxle case
with the 18 bolts.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
NOTICE:
Apply the seal packing or equivalent to the bolts and tighter
them within 10 minutes after application because the bolts
should be seal bolts.

40±54
±
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION WIRE (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
9. ADD AUTOMATIC TRANSAXLE FLUID
10.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
11. RESET MEMORY
(a)1AZ±FE (See pege 05±863)
(b)1AZ±FSE (See pege 05±920)

40122±01
C62929
D25376
C62929
±
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION WIRE (U341E)
40±51
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION WIRE (U341E)
REPLACEMENT
1.REMOVE TRANSMISSION VALVE BODY ASSY (See page 40±42)
2. REMOVE TRANSMISSION WIRE
(a) Removal the bolt and transmission wire.
3. INSTALL TRANSMISSION WIRE
(a) Coat an O±ring with ATF.
(b) Install the transmission wire.
(c) Install the bolt.Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
4.INSTALL TRANSMISSION VALVE BODY ASSY (See page 40±42)
5.RESET MEMORY (See page 05±985)

400DC±02
C83111
AT0103
D25591
D09179
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
40±47
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION VALVE BODY ASSY (U241E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all of the oil
pan bolts, and carefully remove the oil pan assembly. Dis-
card the gasket.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Remove the magnets and use them to collect any
steel chips. Look at the chips and particles in the oil
pan and on the magnet carefully to see the type of
wear which might be found in the tranaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non±magnetic): bearing wear
4. SEPARATE TRANSMISSION WIRE
(a) Disconnect the 5 solenoid valve connectors.
(b) Remove the bolt and lock plate, and separate the ATF
temperature sensor.
5. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
Be careful as some fluid will come out with the oil strainer.

C69150
D03553
C50017
D02938
D02938
AAB
B
B
40±48
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the O±ring from the oil strainer.
6. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy, and remove the 17 bolts and
the valve body assy.
NOTICE:
Be careful not to drop the check ball body and spring.
(b) Remove the check ball body and spring.
(c) Remove the 5 bolts and 5 solenoid valves.
7. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Install the 5 solenoid valves with the 5 bolts.
Torque:
Bolt A: 6.6 N´m (67 kgf´cm, 58 in.
lbf)
Bolt B: 11 N´m (112 kgf´cm, 8 ft ´lbf)
Bolt length:
Bolt A: 12 mm (0.47 in.)
Bolt B: 45 mm (1.77 in.)