2005 TOYOTA AVENSIS open hood

4011Y±01
D30353
Hood Sub±assy
BatteryAir Cleaner Assy
Non±reusable part
: Specified torque


5.0 (51, 44 in.
lbf)
13 (132, 10)
7.0 (71, 62 in.
lbf)
12 (122, 9)
5.0 (51, 44 in.
lbf)26 (265, 19)
39 (409, 29)
39 (400, 29)
Engine Room Cover Side
Radiator Suppot Opening Cover
O±ring
Transmission Oil Filler
Tube Sub±assy
Oil Cooler Inlet Tube No.1
13 (132, 10)Starter Assy Cylinder Head
Cover No.2
5.5 (51, 44 in.
lbf)
12 (122, 9)
Oil Cooler Outlet Tube No.1
35 (357, 25)
ATF Level Gauge
Transmission Control Cable Bracket
12 (122, 9)
12 (122, 9)
Clip
Transmission
Control Cable Assy
11 (110, 8)
Automatic
Transaxle
Assy
Transmission Control
Cable Clamp
Oil Cooler
Tube Clump
N
m (kgf
cm.
ft
lbf)
Battery Carrier
13 (131, 9)
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U341E)
40±9
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSAXLE ASSY (U341E)
COMPONENTS

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.

410DV±01
D30475
13 (133, 10)Hood Sub±assy
Radiator Reserve Tank Assy
Engine Cover No.1
5.0 (51, 44 in.
lbf)
7.0 (71, 62 in.
lbf)
Air Cleaner Assy
Battery Clamp
Sub±assy
3.5 (36, 31 in.
lbf)
Battery
Battery Tray
Clip
Clip
Clip
Floor Shift Transmission
Control Cable Assy
Starter Assy
Starter Connector
Ground Cable
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)
Manual Transmission
Case Protector
64 (653, 47)
40 (408, 30)
20 (200, 14)
8.0 (82, 71 in.
lbf)
40 (408, 30)
64 (653, 47)

Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
12 (120, 9)
5.0 (51, 44 in.
lbf)
64 (653, 47)
Manual Transaxle Assy
13 (133, 10)
37 (380, 27)
46 (469, 34)
13 (130, 9)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.
lbf)
8.0 (82, 71 in.
lbf)
6.0 (61, 53 in.
lbf)
52 (530, 38)
25 (255, 18)
Air Tube No.1
25 (255, 18)
Engine Room Cover Side
Radiator Support
Opening Cover
Clip
13 (131, 9)
12 (120, 9)
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1CD±FTV)
41±31
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1CD±FTV)
COMPONENTS

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.

D30080
41±30
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts. Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Nut: 3.5 N
m (36 kgf
cm, 31 in.
lbf)
59. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
60. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUB±ASSY Torque: 13 N
m (132 kgf
cm, 10 ft
lbf)
64.INSPECT HOOD SUB±ASSY (See page 75±2)
65.ADJUST HOOD SUB±ASSY (See page 75±2)
66.ADD TRANSAXLE OIL (See page 41±5)
67.INSPECT TRANSAXLE OIL (See page 41±2)
68. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
69.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
70.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page)See page 50±9)
71.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
72.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76.BLEED POWER STEERING FLUID (See page 51±4)
77.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
78.INSPECT FLUID LEAK (See page 51±4)
79.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
83.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)

410DT±01
D30082
13 (133, 10)Hood Sub±assy
Engine Cover Sub±assy No.1
Air Cleaner Assy
Battery
Battery Tray
Clip
Clip
Clip
Starter Assy
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)

Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
12 (120, 9)
Manual Transaxle Assy
46 (469, 34)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.
lbf)
Engine Room Cover Side
Radiator Support Opening Cover
44 (449, 32)
44 (449, 32)
Clutch Release Cylinder Assy
Starter
Connector
37 (380, 27)
13 (130, 9)
46 (469, 34)
8.4 (85, 74 in.
lbf)
46 (469, 34)
Transmission Control Cable Assy
Battery Clamp Sub±assy
5.0 (51, 44 in.
lbf)
9.0 (92, 80 in.
lbf)
Back±up Lamp Switch Connector
5.0 (51, 44 in.
lbf)
Clip
26 (260, 19)
40 (410, 30)
64 (653, 47)
52 (530, 38)
13 (131, 9)
41±22
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS

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.

D30480
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±21
AVENSIS REPAIR MANUAL (RM1018E)
51. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts.
Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
52. INSTALL BATTERY TRAY
53. INSTALL BATTERY
54. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Nut: 3.5 N
m (36 kgf
cm, 31 in.
lbf)
55. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
56. INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
57. INSTALL ENGINE ROOM COVER SIDE
58. INSTALL RADIATOR SUPPORT OPENING COVER
59. INSTALL HOOD SUB±ASSY Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
60.INSPECT HOOD SUB±ASSY (See page 75±2)
61.ADJUST HOOD SUB±ASSY (See page 75±2)
62.ADD TRANSAXLE OIL (See page 41±3)
63.INSPECT TRANSAXLE OIL (See page 41±2)
64. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
65.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
66.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
67.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
68.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
69. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
70. STEERING WHEEL CENTER POINT
71.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
72. INSTALL ENGINE UNDER COVER LH
73. INSTALL ENGINE UNDER COVER RH
74. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
75.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)