TOYOTA AVENSIS 2005 Service Repair Manual

400DE±02
D25827
SST
D25828
SST
D25829
SST
0
0.5mm
±
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U241E)
40±57
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (U241E)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE ENGINE UNDER COVER LH
4. 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)
5.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
6.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, pull out the oil seal.SST 09308±00010
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Using SST, pull out the oil seal. SST 09308±00010
9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09316±60011 (09316±00011)
Oil seal drive in depth:
0
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.


D31075
SST
0
0.5mm
40±58
±
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal. SST 09649±17010, 09950±70010 (09951±07150)
Oil seal drive in depth:
0
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD AUTOMATIC TRANSAXLE FLUID
15.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
16. CHECK ABS SPEED SENSOR SIGNAL
(a)ABS WITH EBD SYSTEM (See pege 05±699)
(b)ABS WITH EBD & BA &TRAC & VSC SYSTEM (See pege 05±756)

40124±01
\bD31071
SST
\bD31072SST
\b
D31073SST
±
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U341E)
40±55
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (U341E)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE FRONT FENDER APRON SUB±ASSY LH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. 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)
6.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
7.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
8. REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST, pull out the oil seal.
9. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST, pull out the oil seal.
10. INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.SST 09726±27012 (09726±02041), 09950±70010
(09951±07200)
Oil seal drive in depth:
2.7
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.


D31074
SST
40±56
±
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
11. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Oil seal drive in depth:
0
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
12.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
13.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
14. INSTALL FRONT WHEELS
15. ADD AUTOMATIC TRANSAXLE FLUID
16.INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40±2)
17.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See Page 26±6)
18.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)

4206E±01
D30068
D30069
SST(s)
D30782
RHD Steering Position Type:
LHD Steering Position Type:
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
42±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DRAIN CLUTCH FLUID
2. REMOVE BRAKE MASTER CYLINDER SUB±ASSY (LHD STEERING POSITION TYPE)
(See page 32±13)
3.REMOVE BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 32±19)
4. DISCONNECT CLUTCH RESERVOIR TUBE
(a) Loosen the clip and disconnect the clutch reservoir tubefrom the clutch master cylinder assy.
HINT:
Use a container to catch the fluid.
5. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST(s), disconnect the flexible hose tube. SST 09023±00100
HINT:
Use a container to catch the fluid.
6. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS W/HOLE PIN
(a) Remove the clip and hole pin.

D30782
RHD Steering Position Type:
LHD Steering Position Type:
MP Grease
D30069
SST(s)
D30068
Blue Mark
42±14
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE CLUTCH MASTER CYLINDER ASSY
(a) Remove the 2 nuts clutch master cylinder assy and gasket.
8. INSTALL CLUTCH MASTER CYLINDER ASSY
(a) Install the clutch master cylinder assy and gasket with the 2 nuts. Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
9. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
(a) Apply MP grease to the contact surface of the hole pin and clevis bush.
(b) Connect the clevis to the clutch pedal assy with the hole pin.
HINT:

RHD steering position type:
Install the hole pin from the right side of the vehicle.

LHD steering position type:
Install the hole pin from the left side of the vehicle.
(c) Install the clip to the hole pin.
10. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST(s), connect the flexible hose tube. SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
11. CONNECT CLUTCH RESERVOIR TUBE
(a) Connect the clutch reservoir tube with the clip to the clutch master cylinder assy.
NOTICE:
Connect the clutch reservoir tube so as not be twisted.
12.INSTALL BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 32±19)
13. INSTALL BRAKE MASTER CYLINDER SUB±ASSY (LHD STEERING POSITION TYPE) (See page 32±13)
14.BLEED BRAKE LINE (LHD STEERING POSITION TYPE) (See page 32±4)

±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
42±15
AVENSIS REPAIR MANUAL (RM1018E)
15. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the clutch fluid and bleed clutch sys\
tem.
Torque: 8.4 N
m (85 kgf
cm, 73 in.
lbf)
16. CHECK AND ADJUST BRAKE PEDAL HEIGHT (LHD STEERING POSITION TYPE) (See page 32±6)
17.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (See page 42±2)
18. CHECK BRAKE FLUID LEAKAGE (LHD STEERING POSITION TYPE)
19. CHECK CLUTCH FLUID LEAKAGE
20. CHECK FLUID LEVEL IN RESERVOIR

4202V±03
D30477
LHD Steering Position Type:
RHD Steering PositionType:Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Gasket
Clip
Clutch Master Cylinder Assy
Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Clutch Master Cylinder AssyClip
Gasket
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

12 (120, 9)
12 (120, 9)
15 (155, 11)
15 (155, 11)
MP grease
42±12
± CLUTCHCLUTCH MASTER CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH MASTER CYLINDER ASSY (MTM)
COMPONENTS

4206D±01
D30782
RHD Steering Position Type:
LHD Steering Position Type:
D26300
LHD Steering
Position Type:RHD Steering
Position Type:
42±6
±
CLUTCH CLUTCH PEDAL SUB±ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE INSTRUMENT PANEL SUB±ASSY LOWER (LHD STEERING POSITION TYPE) (See page 71±11)
2.REMOVE COMBINATION METER ASSY (RHD STEERING POSITION TYPE) (See page 71±21)
3. REMOVE CLUTCH PEDAL SPRING
4. REMOVE CLUTCH MASTER CYLINDER PUSH RODCLEVIS W/HOLE PIN
(a) Remove the clip and hole pin.
5. REMOVE CLUTCH PEDAL SUPPORT SUB±ASSY
(a) LHD steering position type: Remove the 2 nuts, bolt and clutch pedal support assy.
(b) RHD steering position type:
Remove the 2 bolts, 2 nuts and clutch pedal support assy.

D30775
D30776
D30781
D30780
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
42±7
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE TURN OVER SPRING SEAT COMPRESSION
SPRING (W/ TURN OVER)
(a) Mount the clutch pedal in a soft jaw vise.
(b) Using a screwdriver, remove the spring.
7. REMOVE CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
8. REMOVE CLUTCH PEDAL TURNOVER BUSH (W/
TURN OVER)
(a) Using a 8 mm hexagon wrench and a hammer, remove
the turn over bush.
9. REMOVE CLUTCH PEDAL SUB±ASSY
(a) Remove the bolt and nut.
(b) Remove the clutch pedal from the clutch pedal support.
10. REMOVE CLUTCH PEDAL PAD
11. REMOVE CLUTCH PEDAL BUSH
(a) Remove the 2 bushes from the clutch pedal.