drain bolt TOYOTA AVENSIS 2005 Service Workshop Manual

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.

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.

40123±01
C62684
AT0103
D30631
D05904O±Ring
40±42
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION VALVE BODY ASSY (U341E)
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 19 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all of the pan
bolts, and carefully remove the oil pan assembly. Discard
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. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful as some fluid will come out with the oil strainer.
(b) Remove the O±ring from the oil strainer.

D30342
D30343
D30346
D30344
40±26
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
11. SEPARATE CONNECTOR
(a) Separate the 2 wire harnesse clamps from the oil filler tube.
(b) Separate the transmission wire connector.
(c) Separate the park/neutral position switch connector.
(d) Separate the 2 speed sensor connectors.
12. REMOVE TRANSMISSION CONTROL CABLE CLAMP
(a) Remove the bolt and transmission control cable clamp from the automatic transaxle.
13. REMOVE TRANSMISSION OIL FILLER TUBE SUB±ASSY
(a) Remove the ATF level gauge.
(b) Remove the bolt and oil filler tube.
(c) Remove the O±ring from the oil filler tube.
14. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
(a) Remove the 3 bolts and control cable bracket No.1.
15. REMOVE FRONT WHEELS
16. REMOVE ENGINE UNDER COVER RH
17. REMOVE ENGINE UNDER COVER LH
18. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug gasket and drain ATF.
(b) Install a new gasket and drain plug. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
19. DRAIN COOLANT
(a)1AZ±FE (See pege 16±19)
(b)1AZ±FSE (See pege 16±31)

C91880
C80991
C91884
40±12
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
10. SEPARATE WIRE HARNESS
(a) Remove the bolt and disconnect the wire harness.
(b) Remove the bolt and disconnect the wire harness clamp bracket.
11. SEPARATE CONNECTOR
(a) Disconnect the transmission wire connector.
(b) Disconnect the park/neutral position switch connector.
(c) Disconnect the speed sensor connector.
12. REMOVE ENGINE UNDER COVER RH
13. REMOVE ENGINE UNDER COVER LH
14.DRAIN COOLANT (See page 16±7) 15. DISCONNECT OIL COOLER INLET TUBE NO.1
(a) Using SST, disconnect the oil cooler inlet tube No.1.SST 09023±12700
16. DISCONNECT OIL COOLER OUTLET TUBE NO.1
(a) Using SST, disconnect the oil cooler outlet tube No.1. SST 09023±12700
17. REMOVE TRANSMISSION OIL FILLER TUBESUB±ASSY
(a) Remove the ATF level gauge.
(b) Remove the 2 bolts, oil cooler tube clamp and oil filler
tube.
(c) Remove the breather hose from the oil filler tube.
(d) Remove the O±ring from the oil filler tube.

C91882
C94723
D25372
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U341E)
40±13
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Disconnect the wire harness clamp.
(b) Remove the 2 bolts and control cable bracket.
19. SEPARATE WIRE HARNESS
(a) Remove the bolt and wire harness.
20. SUSPEND ENGINE ASSY
(a) Install the No.1 and No.2 engine hangers in the correct
direction.
Parts No.:
No.1 engine hanger: 12281±22021
No.2 engine hanger: 12281±15040
Bolt: 91512±B1016
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Attach the engine chain hoist to the engine hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other parts.
21. REMOVE FRONT WHEELS
22. 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)
23.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±2)
24.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
SST 09520±01010, 09520±24010 (09520±32040)
25.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
26. REMOVE STARTER ASSY
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter.
27. SUPPORT AUTOMATIC TRANSAXLE ASSY
(a) Support the automatic transaxle with a transmission jack.

410DY±01
D26902
D26903
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±33
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER RH
8. REMOVE ENGINE UNDER COVER LH
9. DRAIN TRANSAXLE OIL
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18.REMOVE AIR TUBE NO.1 (See page 14±286)
19. SEPARATE RADIATOR RESERVE TANK ASSY
(a) Remove the 2 bolts, separate the radiator reserve tankassy.
20. REMOVE STARTER ASSY
(a) Remove the nut, disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.

410DU±01
D30480
D30081
41±24
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER SUB±ASSY NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19.REMOVE STARTER ASSY (See page 19±12) 20. SEPARATE WIRE HARNESS
(a) Remove the 3 bolts, and separate the 3 wire harnesses.

4105X±04
D30480

D30691
D30482
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±15
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE CYLINDER HEAD COVER NO.2
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19. DISCONNECT WIRE HARNESS
(a) Remove the 3 bolts, disconnect the wire harness clamps.
(b) Remove the bolt, disconnect the ground cable.

I35333
I35333
(1)(2)
(3)
(4)
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1CD±FTV)
55±87
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
11. INSPECT COMPRESSOR OIL
(a) When replacing the w/pulley compressor assy with a new one, after gradually \
removing the refrigerant gas from the service valve, drain the following amount of oil from the new w\
/pulley compressor assy
before installation.
Standard:
(Oil capacity inside new w/pulley compressor assy: 90 + 15 cc (3.0 + 0.5 fl. oz.) ) ± (Remaining
oil amount in the removed w/pulley compressor assy) = (Oil amount to be r\
emoved when replac-
ing)
NOTICE:

When checking the compressor oil level, observe the precautions on the cooler removal/inst\
al-
lation.

Since compressor oil remains in the pipes of the vehicle, if a new w/pulley c\
ompressor assy
is installed without removing some oil inside, the oil amount becomes ex\
cessive, preventing
heat exchange in the refrigerant cycle and causing refrigerant failure.

If the remaining oil in the removed w/pulley compressor assy is too smal\
l in volume, check for
oil leakage.

Be sure to use ND±OIL 8 for compressor oil.
12. INSTALL W/PULLEY COMPRESSOR ASSY
(a) Install the w/pulley compressor assy with the 4 bolts.Torque: 29 N
m (300 kgf
cm, 21 ft
lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to
install the w/pulley compressor assy.
(b) Connect the connector.
13. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
14. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55±46)
15. FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)