TOYOTA AVENSIS 2005 Service Repair Manual

D25834
SST
−
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U151E)
40−25
AVENSIS Supplement (RM1045E)
10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
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 á 0.5 mm (0 á 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
11 . INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30 −4)
1 2. INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30 −4)
1 3. INSTALL FRONT WHEELS
Torque: 103 N
m( 1,050 kgf
cm, 76 ft
lbf)
1 4. ADD AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE40 −2)
1 5. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE40 −2)
1 6. CHECK ABS SPEED SENSOR SIGNAL
(a) ABS WITH EBD & BA &TRAC & VSC SYSTEM (SEE PUB, NO. RM1018E, PAGE 5 −756)

40188−01
C91925
D30865
AT0103
C91927
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
40−19
AVENSIS Supplement (RM1045E)
TRANSMISSION VALVE BODY ASSY (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 47 N
m (479 kgf
cm, 35 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.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Collect any steel chips with the removed magnets.
Look at the chips and particles in the pan and on the
magnets carefully to see the type of wear which
might be found in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.

C91931
C91932
C91933
F46566
40−20
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
AVENSIS Supplement (RM1045E)
5. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful that some fluid will come out of the oil strainer.
(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, spring and accu-
mulator piston.
(b) Remove the check ball body and spring.

D30644
F46566
D30644
AB
B
C
D
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
40−21
AVENSIS Supplement (RM1045E)
(c) Remove the 5 bolts, 3 lock plates and 7 shift solenoid
valves.
7. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Install the spring and check ball body.
(b) Install the 7 shift solenoid valves and 3 lock plates with
the 5 bolts.
Torque:
Bolts A, B:11N·m (110 kgf·cm, 8 ft.
lbf)
Bolts C, D: 6.6 N·m (67 kgf·cm, 58 in. lbf)
Bolt length:
Bolt A:16 mm (0.63 in.)
Bolt B: 57 mm (2.24 in.)
Bolt C: 20 mm (0.79 in.)
Bolt D:12 mm (0.47 in.)

C91933
A
B
CB
B
B
A
CCC
L
L
C
B
C91932
C91931
C91927
40−22
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
AVENSIS Supplement (RM1045E)
(c) Align the groove of the manual valve with the pin of the
lever.
(d) Install the 17 bolts.
Torque:11N
m(110 kgf
cm, 8 ft
lbf)
NOTICE:
SPush the valve body against the accumulator piston
spring and the check ball body to install it.
SFirst, temporarily tighten those bolts marked byLin
the illustration because they are positioning bolts.
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 41mm (1.614 in.)
8. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O−ring with ATF.
(b) Install the O−ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque:11N
m(110 kgf
cm, 8 ft
lbf)
9. INSTALL TRANSMISSION WIRE
(a) Coat an O−ring 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 7 shift solenoid valve connectors.

D30865
C91925
−
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E)
40−23
AVENSIS Supplement (RM1045E)
10. I NSTALL AUTO M AT I C TRANSAXLE O I L PAN
SUB −ASSY
(a) Install the 2 magnets to the oil pan.
(b) Apply seal packing to the 18 bolts. Seal packing:
THREE BOND 1344 or equivalent
(c) Install a new gasket, the oil pan and 18 bolts to the trans- axle case.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
NOTICE:
Apply seal packing to the bolts and tighten them within 10
minutes of application.
11 . ADD AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
1 2. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
1 3. RESET MEMORY (SEE PAGE 05 −54 1)

40187−01
C91925
D30865
AT0103
C91927
40−16
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
AVENSIS Supplement (RM1045E)
TRANSMISSION WIRE (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 47 N
m (479 kgf
cm, 35 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.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Collect any steel chips with the removed magnets.
Look at the chips and particles in the pan and on the
magnets carefully to see the type of wear which
might be found in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.

D30866
D30867
D30866
C91927
D30865
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
40−17
AVENSIS Supplement (RM1045E)
5. REMOVE TRANSMISSION WIRE
(a) Disconnect the transmission wire connectors.
(b) Remove the bolt and transmission wire.
6. INSTALL TRANSMISSION WIRE
(a) Coat an O−ring of the transmission wire connector with
AT F.
(b) Install the transmission wire and 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 7 shift solenoid valve connectors.
8. INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing to the 18 bolts.
Seal packing:
THREE BOND1344 or equivalent

C91925
40−1 8
−
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION WIRE (U151E)
AVENSIS Supplement (RM1045E)
(c) Install a new gasket, the oil pan and 18 bolts to the trans- axle case.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
NOTICE:
Apply seal packing to the bolts and tighten them within 10
minutes of application.
9. ADD AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
1 0. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
11 . RESET MEMORY (SEE PAGE 05 −54 1)

141Q9−01
A36642
A13397
A13400
14−56
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
HINT:
The connecting rod cap bolts are tightened in 2 progressive
steps.
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure the correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring the correct reassembly.
(b) Using a 12 mm socket wrench, remove the 2 connecting
rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and the lower bearing by wiggling
the connecting rod cap right and left.
HINT:
Keep the lower bearing inserted to the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
(f) Lay a strip of Plastigage on the crank pin.