oil type TOYOTA AVENSIS 2005 Service Workshop Manual

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.

F44798
F44799
F44793Matchmarks
±
STEERING COLUMN STEERING COLUMN ASSY
50±15
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE UN±LOCK WARNING SWITCH ASSY
(a) Slide the unlock warning switch assy out of the steering column upper br\
acket.
39. REMOVE IGNITION OR STARTER SWITCH ASSY
(a) Remove the 2 screws and ignition or starter switch assy.
40. INSTALL IGNITION OR STARTER SWITCH ASSY
(a) Install the ignition or starter switch assy to the steering column upper w/swit\
ch bracket assy with the
2 screws.
41. INSTALL UN±LOCK WARNING SWITCH ASSY
(a) Install the un±lock warning switch assy.
(b) Connect the un±lock warning switch assy connector to the ignition or \
starter switch assy.
42. INSTALL IGNITION SWITCH LOCK CYLINDER ASSY
(a) Make sure of the ignition switch lock cylinder assy at the ACC position.\
(b) Install the ignition switch lock cylinder assy.
43. INSPECT STEERING LOCK OPERATION
(a) Check that the steering lock mechanism is activated when removing the ke\
y.
(b) Check that the steering lock mechanism is deactivated when inserting the\
key and turning it to ACC position.
44. INSTALL TRANSPONDER KEY AMPLIFIER
(a) Align the transponder key amplifier with the installationposition of the upper bracket with the amplifier inclined.
(b) Push the transponder key amplifier up and connect it to the upper bracket.
NOTICE:
Take care not to push the amplifier up with excessive force
to prevent it from being damaged.
45. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
(a) Temporarily install the steering column upper with switch bracket assy and steering column upper clamp with 2 new
tapered±head bolts.
(b) Tighten the 2 tapared±head bolts until the bolt heads break off.
46. INSTALL STEERING SLIDING YOKE SUB±ASSY (RHD STEERING POSITION TYPE)
(a) W/VSC:
Install the steering sensor (See page 32±65).
(b) Align matchmarks on the steering sliding yoke and steer- ing main shaft.
(c) Oil Pressure Power Steering
(1) Install the steering sliding yoke with the bolt.
Torque: 28 N
m (286 kgf
cm, 21 ft
lbf)

F44793Matchmarks
F44789
RHD:
Matchmarks
A
B
F45709
50−16
−
STEERING COLUMN STEERING COLUMN ASSY
(d) Electric Pressure Power Steering
(1) Install the steering sliding yoke with the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
47. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (LHD STEERING POSITION TYPE)
(a) W/VSC:
Install the steering sensor (See page 32− 65).
(b) Align matchmarks on the steering intermediate shaft assy
No. 2 and steering main shaft.
(c) Oil Pressure Power Steering (1) Install the steering intermediate shaft assy No. 2
with the bolt.
Torque: 28 N
m (286 kgf
cm, 21 ft
lbf)
(d) Electric Pressure Power Steering (1) Install the steering intermediate shaft assy No. 2
with the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
48. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (RHD STEERING POSITION TYPE)
(a) Temporarily install the steering intermediate shaft assy No. 2 with the bolt A.
49. INSTALL STEERING SLIDING YOKE SUB −ASSY (LHD STEERING POSITION TYPE)
(a) Temporarily install the steering sliding yoke with the bolt A.
50. INSTALL STEERING COLUMN ASSY
(a) Install the steering column assembly with the 3 bolts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(b) RHD: Align the matchmarks on the intermediate shaft assy No.
2 and steering intermediate shaft.
(c) RHD: Install the bolt B and tighten the bolt A.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
HINT:
When replacing the intermediate shaft assy No. 2 with a new
one, set the front tires in the straight ahead position and make
the bolt hole for the intermediate shaft assy No. 2 and extension
face straight rearward as illustrated, and install the bolt.

5006X−01
Steering
Column
Protector No.1
F44781
Horn Button Assy
Steering Wheel Assy
Spiral Cable Sub −Assy
Steering Column Cover
Headlamp Dimmer Switch AssySteering Column Assy
Steering
Sliding Yoke
Sub− Assy
Steering Intermediate
Shaft Assy No.2
Column Hole Cover Silencer Sheet
Steering Column Cover LWR
Windshield Wiper
Switch Assy
N

m (kgf
cm, ft
lbf): Specified torque
OIL Pressure Power Steering:
Steering Intermediate
Shaft Assy No.2
Steering
Sliding Yoke
Sub−Assy
35 (360, 26)
Column Hole Cover
Silencer Sheet
LHD Steering Position Type:
LHD Steering Position
Type: w/ Instrument Cluster
Finish Panel Assy
Floor Shift
Parking Lock Cable
Assy (A/T Transaxle)
Instrument Panel
Hole Cover
5 (51, 44 in.




lbf)
18 (184, 13)
18 (184, 13)
Instrument Panel
Airbag Assy
18 (184, 13)
18 (184, 13)
18 (184, 13)
25 (255, 18)
50 (510, 37)
35 (360, 26)
35 (360, 26)
28 (286, 21)
35 (360, 26)
28 (286, 21)
25 (255, 18)
25 (255, 18)
−
STEERING COLUMN STEERING COLUMN ASSY
50−5
STEERING COLUMN ASSY
COMPONENTS

C62956
D30058
1CD±FTV Engine Type: Others:
Transaxle Side


D25281
AB
C62958
± CLUTCHCLUTCH UNIT (MTM)
42±27
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE CLUTCH DISC ASSY
NOTICE:
Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub±assy
away from oil and foreign attachment.
9. INSPECT CLUTCH DISC ASSY
(a) Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assy as necessary.
(b) Install the clutch disc assy to the transaxle assy.
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
(c) Using a dial gage, check the clutch disc assy runout.
Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assy as necessary.
10. INSPECT CLUTCH COVER ASSY
(a) Using vernier calipers, inspect the diaphragm spring for
the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assy as necessary.
11. INSPECT FLYWHEEL SUB±ASSY
(a) Using a dial gage, inspect the flywheel sub±assy runout.
Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub±assy as necessary.

Z15500
Oil
ReservoirPS Vane
Pump
PS Gear
SST(s)
Open
Lock Position
F08858
±
POWER STEERING POWER STEERING SYSTEM
51±7
AVENSIS REPAIR MANUAL (RM1018E)
(k) With the engine idling and valve fully opened, turn the
steering wheel to full lock position.
Minimum fluid pressure:
AZ Series:
8,300 to 9,000 kPa (85 to 92 kgf/cm
2, 1,204 to 1,305 psi)
1CD±FTV:
8,800 to 9,500 kPa (90 to 97 kgf/cm
2, 1,276 to 1,378 psi)
NOTICE:

Do not maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(l) Remove SST(s).
(m) AZ Series:
Connect the pressure feed tube assy to the vane pump
assy (See page 51±9).
(n) 1CD±FTV:
Connect the pressure feed tube assy to the vane pump
assy (See page 51±19).
(o) Bleed the power steering system.
5. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b)Remove the steering wheel pad (See page 60±17).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions. Steering effort (Reference):
5.5 N´m (56 kgf´cm, 49 in.´lbf)
HINT:
Take the tire type, pressure and contact surface into consider-
ation before making your diagnosis.
(e) Torque the steering wheel set nut. Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
(f)Install the steering wheel pad (See page 60±17).

I35332
I35330
I35331
55±88
± HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
16. INSTALL COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant discharge hose
No.1.
(d) Install the cooler refrigerant discharge hose No.1 on the
w/pulley compressor assy with the bolt.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
17. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1 (RHD STEERING POSITION TYPE)
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant suction hose
No.1.
(d) Install the cooler refrigerant suction hose No.1 on the w/
pulley compressor assy with the bolt.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
18. INSTALL SUCTION SERVIC VALVE (LHD STEERING
POSITION TYPE)
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the suction service valve.
(d) Install the suction servic valve on the w/pulley compres-
sor assy with the 2 bolts.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
19. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD STEERING POSITION TYPE)
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant suction hose
No.1.

I35344
I35343
I35342
I35336
± HEATER & AIR CONDITIONERW/RECEIVER CONDENSER ASSY
55±97
AVENSIS REPAIR MANUAL (RM1018E)
20. I N S TA L L M A G N E T VA LV E A S S Y ( W / H O T G A S
HEATER)
(a) Install the magnet valve assy with the 4 bolts.
Torque: 3.4 N
m (35 kgf
cm, 30 in.
lbf)
21. INSTALL REFRIGERANT FILTER (W/ HOT GAS
HEATER)
(a) Install the refrigerant filter to the discharge tube.
22. INSTALL DISCHARGE TUBE (W/ HOT GAS HEATER)
(a) Install the discharge tube with the 2 bolts.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
23. INSTALL LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV)
STEERING POSITION TYPE)
(a) Remove the attached vinyl tape from the tube and the
connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the pipe joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the liquid tube sub±assy B.
(d) Install the liquid tube sub±assy B on the w/ receiver con-
denser assy with the bolt.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
24. INSTALL DISCHARGE TUBE SUB±ASSY (W/ HOT
GAS HEATER)
(a) Remove the attached vinyl tape from the tube and the
connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to a new 2 O±rings and
the fitting surface of the pipe joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the discharge tube sub±assy.

760WY±01
B67425
Claw
B67431
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
76±3
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1. REMOVE FRONT BUMPER COVER
(a) Put protective tape under the front fender.
HINT:
Because the spoiler covers LH and RH are assembled, remove
them together.
(b) Remove the spoiler.
(1) Remove the 9 screws and 6 claws.
(2) Remove the 6 retainers.
(3) Remove the spoiler covers LH and RH together.
(4) Remove the bolt and separate the spoiler cover RH
from the LH.
(c) Remove the 3 bolts and 2 clips.
(d) Using a screwdriver, disengage the 6 claws and remove
the bumper cover.
HINT:
Tape the screwdriver tip before use.
(e) w/ Fog lamp:
Disconnect the fog lamp connectors.
2. R E M O V E H E A D L A M P WA S H E R A C T U ATO R
SUB±ASSY LH (W/ HEADLAMP CLEANER)
(a) Remove the washer hose clip.
(b) Using a screwdriver, pry out the front washer nozzle.
HINT:
Tape the screwdriver tip before use.
(c) Remove the 2 screws and actuator.
3. REMOVE HEADLAMP WASHER ACTUATOR SUB±ASSY RH (W/ HEADLAMP CLEANER)
HINT:
Use the same procedures described for the LH side.
4. REMOVE INTERCOOLER COOLING AIR DUCT SUB±ASSY (W/ CAC 1CD±FTV ENGINE TYPE)
(a) Remove the 3 screws and air duct.
5. REMOVE FRONT BUMPER REINFORCEMENT SUB±ASSY
(a) Using a screwdriver, remove the wire harness.
(b) Remove the 8 bolts and reinforcement.
6. REMOVE FRONT BUMPER SIDE RETAINER LH
(a) Using a screwdriver, remove the 2 screws and retainer.
HINT:
Tape the screwdriver tip before use.

D09176
D09177
AT0103
D09637
40±16
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. FIX AUTOMATIC TRANSAXLE ASSY
10. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the 18 bolts.
(b) Remove the oil pan and 2 magnets.
11. REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET
(a) Remove the gasket from the oil pan.
12. INSPECT AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non±magnetic).... bushing wear
13. REMOVE TRANSMISSION WIRE
(a) Remove the 5 connectors from the shift solenoid valves.
(b) Remove the bolt, clamp and ATF temperature sensor.