Piston TOYOTA AVENSIS 2005 Service Service Manual

A77479
Upward
No. 1
No. 2
Painted Mark
Code Mark (2T)
A77480
Front
Side Rail UpperSide Rail Lower
No. 2 Expander
Compression No. 1 and
A53029
A33379
14±66
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
30. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the painted mark facing right side.
NOTICE:
Install the compression ring No. 2 with the code mark (2T)
upward.
(c) Position the piston rings so that the ring ends are as
shown.
31. INSTALL CRANKSHAFT BEARING
(a) Install the upper bearing with an oil groove on cylinder
block.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the cylinder block and keep them free of oils.
32. INSTALL CRANKSHAFT BEARING NO.2
(a) Install the lower bearing on bearing cap.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the cylinder block and keep them free of oils.

A13501
A77275Front Mark and Journal Number
A77475


10    
A77470
90
Engine FrontPaint
Mark
A77481
Claw
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±67
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
33. INSTALL CRANKSHAFT THRUST WASHER UPPER
(a) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.
34. INSTALL CRANKSHAFT
(a) Apply engine oil on the upper bearing and install the
crankshaft on the cylinder block.
(b) Apply engine oil on the lower bearing.
(c) Examine the front marks and install the bearing caps to
the cylinder block.
(d) Apply a light coat of engine oil on the threads of the bear-
ing cap bolts.
(e) Using several steps, tighten the bolts with the specified
torque in the sequence shown in the illustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(f) Retighten the bolts in the same way as above with the
specified torque.
Torque: 40 N
m (408 kgf
cm, 29 ft
lbf)
(g) Place the front mark on each bearing cap bolt head with
paint.
(h) Retighten the bearing cap bolts by 90 in the same se-
quence as step (e).
(i) Check that each painted mark is now at a 90angle to
the front.
(j) Check that the crankshaft turns smoothly.
35. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the bearing cap and keep them free of oils.
36. INSTALL PISTON SUB±ASSY W/CONNECTING ROD
NOTICE:
The connecting rod cap bolts are tightened in 2 progres-
sive steps.

A77482
Front Mark
Front
A77483
Front Mark
A77470
90

Engine FrontPaint
Mark 14±68
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(a) Apply engine oil on the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
(d) Check that the protrusion of the connecting rod cap is fac-
ing the correct direction.
(e) Apply a light coat of engine oil on the threads of the con-
necting rod cap bolts.
(f) Using a 12 mm socket wrench, tighten the bolts in several
steps with the specified torque.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
SST 09011±38121
(g) Place the front mark on each connecting cap bolt head
with paint.
(h) Retighten the cap bolts by 90
as shown in the illustration.
(i) Check that each painted mark is at a 90
angle to the
front.
(j) Check that the crankshaft turns smoothly.

141BT±01
A77367
Piston Ring Set
Snap Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Bearing
Cylinder Block Assy
Crankshaft Thrust Washer
Crankshaft Bearing
Crankshaft
Crankshaft Bearing
Ring Pin
Crankshaft Bearing Cap BoltConnecting Rod Bearing
Connecting Rod Bearing 14±52
± ENGINE MECHANICALCYLINDER BLOCK ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
CYLINDER BLOCK ASSY
COMPONENTS

4002J±01
D03796
SST
C67862
C67865
C67863
40±56
± AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
SECOND BRAKE PISTON ASSY (U34#E Series)
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB±ASSY
[ 35608L / 3509 ]
(a) Place SST on the piston return spring and compress.
SST 09387±00060
(b) Using a screwdriver, remove the snap ring.
(c) Remove the 2nd brake return spring from the 2nd brake
cylinder.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB±ASSY
[ 35608L / 3509 ]
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 14.65 mm (0.5768 in.)
3. REMOVE 2ND BRAKE PISTON
[ 35624E / 3509 ]
(a) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf
cm
2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.

C67864
C67864
C67866
C67862
D03796
SST
± AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U34#E Series)
40±57
U340E A/T REPAIR MANUAL (RM824E)
4. REMOVE 2ND BRAKE CYLINDER O±RING
[ 35664D / 3509 ]
(a) Using a screwdriver, remove the 2 O±rings from the 2nd
brake cylinder.
5. INSTALL 2ND BRAKE CYLINDER O±RING
[ 35664D / 3509 ]
(a) Install 2 new O±ring to the 2nd brake cylinder.
NOTICE:
Be careful not to damage the O±ring.
6. INSTALL 2ND BRAKE PISTON
[ 35624E / 3509 ]
(a) Coat 2 new O±rings with ATF and install them in the 2nd
brake cylinder.
(b) Be careful not to damage the O±rings and press in the
2nd brake piston into the 2nd brake cylinder with a your
hands.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB±ASSY
[ 35608L / 3509 ]
(a) Install the piston return spring.
(b) Place SST on the piston return spring, and compress the
piston return spring with a press.
SST 09387±00060
(c) Using a screwdriver, install the snap ring.
NOTICE:
Be sure the end gap of the snap ring is not aligned with the
piston return spring claw.

9808U±01
± COMPONENTS151350
98±7
3510/PLANETARY GEAR, REVERSE PISTON & COUNTER
GEAR(ATM)
(0008± )NZE121..ATM U340E

4002L±01
C67881
D08358
C59838
C67883
40±64
± AUTOMATIC TRANSMISSION / TRANSTRANSAXLE REAR COVER ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
TRANSAXLE REAR COVER ASSY (U34#E Series)
OVERHAUL
1. REMOVE TRANSAXLE REAR COVER PLUG
[ 35102B / 3503 ]
(a) Remove the 4 transaxle rear cover plug from the trans-
axle rear cover.
(b) Using a screwdriver, remove the O±ring from the trans-
axle rear cover plug.
2. REMOVE OVERDRIVE BRAKE RETURN SPRING
SUB±ASSY
[ 34603B / 3509 ]
(a) Using SST, a press and a screwdriver, remove the snap
ring.
SST 09387±00070
NOTICE:
Stop the press when the O/D brake piston is lowered 1 ± 2
mm (0.039 ± 0.078 in.) from the snap ring groove, prevent-
ing the O/D brake piston from being deformed.
(b) Remove the O/D brake return spring.
3. INSPECT OVERDRIVE BRAKE RETURN SPRING
SUB±ASSY
[ 34603B / 3509 ]
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.88mm (0.7039 in.)
4. REMOVE 2ND COAST & OVERDRIVE BRAKE PISTON
[ 34622B / 3509 ]
(a) Apply compressed air (392 kPa, 4.0 kgf
cm
2, 57 psi) to the
transaxle rear cover to remove the O/D brake piston.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, holding it with your hand
using a waste cloth.

Take care not to splash ATF when air±blowing.

C67884
C67885
HoldTurn
SST
C82194



C67888
D25116
A
± AUTOMATIC TRANSMISSION / TRANSTRANSAXLE REAR COVER ASSY (U34#E Series)
40±65
U340E A/T REPAIR MANUAL (RM824E)
5. REMOVE 2ND COAST & OVERDRIVE O±RING
[ 34622C / 3509 ]
(a) Using a screwdriver, remove the 2 O±ring from the 2nd
coast & O/D brake piston.
6. REMOVE CLUTCH DRUM OIL SEAL RING
[ 35617G / 3507 ]
(a) Remove the 3 oil seals.
7. REMOVE TRANSAXLE REAR COVER NEEDLE
ROLLER BEARING
[ 35102D / 3503 ]
(a) Using SST, remove the bearing.
SST 09387±00040 (09387±01020)
8. INSTALL TRANSAXLE REAR COVER NEEDLE
ROLLER BEARING
[ 35102D / 3503 ]
(a) Using SST and a press, install the new bearing to the
transaxle rear cover.
SST 09950±60010 (09951±00190, 09952±06010),
09950±70010 (09951±07100)
Standard clearance: 25.2 mm (0.992 in.)
9. INSTALL CLUTCH DRUM OIL SEAL RING
[ 35617G / 3507 ]
(a) Compress the oil seal ring from both sides to reduce di-
mension A.
Dimension A: 5.0 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the transaxle
rear cover.

C67884
C67889
D08358
C67881
40±66
± AUTOMATIC TRANSMISSION / TRANSTRANSAXLE REAR COVER ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL 2ND COAST & OVERDRIVE O±RING
[ 34622C / 3509 ]
(a) Coat the 2 new O±rings with ATF, install them to the trans-
axle rear cover.
NOTICE:
Be careful not to damage the oil seal lip.
11. INSTALL 2ND COAST & OVERDRIVE BRAKE PISTON
[ 34622B / 3509 ]
(a) Coat the piston with ATF, install it to the transaxle rear cov-
er.
NOTICE:
Be careful not to damage the oil seal lip.
12. INSTALL OVERDRIVE BRAKE RETURN SPRING
SUB±ASSY
[ 34603B / 3509 ]
(a) Using SST and a press, install the O/D brake return spring
and snap ring to the transaxle rear cover.
SST 09387±00070
NOTICE:
Stop the press when the O/D brake piston is lowered 1 ± 2
mm (0.039 ± 0.078 in.) from the snap ring groove, prevent-
ing the O/D brake piston from being deformed.
13. INSTALL TRANSAXLE REAR COVER PLUG
[ 35102B / 3503 ]
(a) Install 4 new O±rings and the 4 screw plugs to the trans-
axle rear cover.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
NOTICE:
Be careful not to damage the oil seal lip.