TOYOTA AVENSIS 2005 Service Repair Manual

4100Z±05
D25304
0 to 5 mm
(0 to 0.20 in.) 41±2
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE OIL (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE OIL (MTM)
ON±VEHICLE INSPECTION
1. INSPECT TRANSAXLE OIL
(a) Stop the vehicle on the level place.
(b) Remove the transmission filler plug and gasket.
(c) Check that the oil surface is within 5 mm (0.20 in.) from the
lowest position of the inner surface of the transmission fill-
er plug opening.
NOTICE:

Excessively large or small amount of oil may cause
troubles.

After replacing oil, drive the vehicle and check the oil
level.
(d) Check for oil leakage when the oil level is low.
(e) Install the transmission filler plug and new gasket.
Torque:
C50, C250: 39 N
m (400 kgf
cm, 29 ft
lbf)
E354, E357: 49 N
m (500 kgf
cm, 36 ft
lbf)

4100Y±05
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM (MTM)
41±1
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.

: (C50 MANUAL TRANSAXLE Repair Manual Pub. No. 826E or C250 MANUAL TRANS\
AXLE Repair
Manual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E\
)
SymptomSuspect AreaSee page
Noise
6. Oil (Level low)
7. Oil (Wrong) C50/C250
E354/E357
8. Gear (Worn or damaged)
9. Bearing (Worn or damaged)41±2
41±3
41±5



Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged) C50/ C250 E354/E357
4. O±Ring (Worn or damaged)41±2


41±3
41±5

Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)41±7




Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)

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.

C80202
C81293
C88567
C95378
2
1Lock Key
D28033
Shift Lever Plate
± AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT PARKING LOCK CABLE ASSY
40±75
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using a screwdriver, disconnect the cable from the upper
bracket.
13. INSTALL FLOOR SHIFT PARKING LOCK CABLE
ASSY
(a) Turn the ignition switch to ACC or ON.
(b) Connect the cable to the upper bracket.
(c) Connect the cable clamp.
(d) Shift the shift lever to the P position.
(e) Using a small screwdriver, unlock the claw of the lock key
of the automatic adjustment part.
(f) Pass the parking lock cable through the hole of the shift
lever plate.
(g) Insert the slide cap into the shift lever plate.

D28034Shift Lock Release Link
C63997
40±76
±
AUTOMATIC TRANSMISSION / TRANS FLOOR SHIFT PARKING LOCK CABLE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(h) Apply MP grease to the shift lock release link.
(i) Insert the lever pin into the hole in the cable end.
(j) Lock the lock key.
HINT:
At this time, the shift lever should be in the P position and the
ignition key should be set to Lock.
14.INSTALL INSTRUMENT PANEL AIR BAG ASSY (See page 60±29)
15.INSPECT INSTRUMENT PANEL AIR BAG ASSY (See page 60±29)
16.INSPECT SRS WARNING LIGHT (See page 05±1184)
17.CHECK KEY INTERLOCK OPERATION (See page 40±59)

4011M±01
C83114
Clip
Bracket
Park/Neutral
Position Switch
Control Shaft Lever Assy
C83873
Exhaust Pipe
Assy Front
Stabilizer Bar Front
40±70
±
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION CONTROL CABLE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION CONTROL CABLE ASSY
REPLACEMENT
1.REMOVE INSTRUMENT PANEL LOWER ASSY (See page 71±11)
2.REMOVE AIR CONDITIONING RADIATOR ASSY (See page 55±55)
3.REMOVE EXHAUST PIPE ASSY FRONT (1ZZ±FE ENGINE TYPE) (See page 15±2)
4.REMOVE EXHAUST PIPE ASSY FRONT (1AZ±FE/1AZ±FSE ENGINE TYPE) (See page 15±7) 5. REMOVE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the nut and disconnect the transmission controlcable assy from the control shaft lever assy.
(b) Remove the clip and disconnect the transmission control cable assy from the bracket.
(c) Disconnect the control cable from the control cable sup-
port.
(d) Remove the 2 nuts and separate the transmission control cable assy from the body.

D28032
Shift Lever
Plate
Cable Outer
Cable End
C88568
C88568
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION CONTROL CABLE ASSY
40±71
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using a fine screw driver, separate the cable outer of the
transmission control cable assy from the shift lever plate.
(f) Using a screw driver, disconnect the transmission control
cable end from the floor shift assy.
(g) Remove the 2 bolts.
(h) Pull out the transmission control cable assy from the
body.
(i) Remove the retainer from the transmission control cable
assy.
6. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Install the retainer to the transmission control cable assy.
(b) Pull the transmission control cable assy into the body.
(c) Install the 2 bolts.
Torque: 5.0 N
m (50 kgf
cm, 43 in.
lbf)
(d) Shift the shift lever to the N position.

D28032
Shift Lever
Plate
Projection
Cable Outer
Projection
Cable End
C83873
Exhaust Pipe
Assy Front
Stabilizer Bar Front
C83114
Clip
Bracket
Park/Neutral
Position Switch
Assy
Control Shaft Lever
40±72
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION CONTROL CABLE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(e) Install the control cable to the shift lever plate.
(f) Connect the control cable end to the floor shift assy.
HINT:
Install it with the uneven surface facing up.
NOTICE:

Be sure to face up the projection on the cable end to
prevent torsion on the inner cable.

Be sure to face up the projection on the outer cable
while installing the outer cable to the shift lever plate.

Make sure that the ends of the hooks are open while
installing the outer cable to the shift lever plate.
(g) Install the control cable with the 2 nuts to the body.
Torque: 5 N
m (50 kgf
cm, 43 in.
lbf)
(h) Connect the control cable to the control cable support.
(i) Temporarily install the control cable to the control shaft le-
ver with the nut.
(j) Install the control cable with the clip to the bracket.
NOTICE:
Set the shift position to N. Connect the transmission con-
trol cable to the control shaft lever on the transmission
assy.
At that time, pull the end of the control cable and release it
until back±lash (looseness) in the cable is removed. Then
tighten the nut.

±
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION CONTROL CABLE ASSY
40±73
AVENSIS REPAIR MANUAL (RM1018E)
7. INSTALL INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY
(See page 71±11)
8.ADJUST SPIRAL CABLE SUB±ASSY (See page 60±26)
9.INSTALL STEERING WHEEL ASSY (See page 50±9)
10.INSTALL HORN BUTTON ASSY (See page 60±17)
11.INSTALL EXHAUST PIPE ASSY FRONT (1ZZ±FE ENGINE TYPE) (See page 15±2)
12.INSTALL EXHAUST PIPE ASSY FRONT (1AZ±FE/1AZ±FSE ENGINE TYPE) (See page 15±7)
13.INSPECT HORN BUTTON ASSY (See page 60±17)
14.INSPECT SRS WARNING LIGHT (See page 05±1184)
15. CHECK FOR EXHAUST GAS LEAKS
16.ADJUST SHIFT LEVER POSITION (See page 40±69)
17.INSPECT SHIFT LEVER POSITION (See page 40±69)
18.CHARGE REFRIGERANT (See page 55±38)
SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
19.INSPECT LEAKAGE OF REFRIGERANT (See page 55±38)

400DI±02
D25118
D25119
± AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT ASSY
40±69
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When the shift lever from P to R position with the ignition switch is ON and the brake pedal is de-
pressed, make sure that the shifting lever moves smoothly and can be moderately operated.
(b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position
and moves rearward when shifting to R position.
2. ADJUST SHIFT LEVER POSITION
(a) Loosen the nut on the control shaft lever.
(b) Push the control shaft fully downward.
(c) Return the control shaft lever 2 notches to N position.
(d) Set the shift lever to N position.
(e) While holding the shift lever lightly toward the R position
side, tighten the shift lever nut.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
(f) Start the engine and make sure that the vehicle moves
forward when shifting the lever from N to D position and
moves rearward when shifting it to R position.