2005 TOYOTA AVENSIS clutch

± INTRODUCTIONTERMS
01±13
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

A82647
Length
A82648
No Continuity
A82649
Free Lock
A82650
Apply Grease
A82651
± STARTING & CHARGINGSTARTER ASSY
19±5
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
9. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the starter brush
holder assy.
(b) Check the brush holder.
(1) Using an ohmmeter, check that there is no continu-
ity between the positive (+) and negative (±) brush
holders.
If there is continuity, repair or replace the starter commutator
end frame assy.
10. INSPECT REPAIR SERVICE STARTER KIT
(a) Check the starter clutch.
(1) Rotate the clutch pinion gear counterclockwise and
check that it turns freely. Try to rotate the clutch pin-
ion gear clockwise and check that it locks.
If necessary, replace the repair service starter kit.
11. INSTALL PLANET GEAR
(a) Apply grease to the planet gears and pin parts of the plan-
etary shaft.
(b) Install the 3 planet gears.
12. INSTALL STARTER BRUSH HOLDER ASSY
(a) Install the brush holder to the starter armature assy.

010BZ±02
01±6
± INTRODUCTIONTERMS FOR MANUAL TRANSAXLE REPAIR MANUAL
C250 M/T REPAIR MANUAL (RM1020E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Toyota equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric Pressure±
CACCharge Air CoolerInter cooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft positionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle Potion±
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Control TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only
memoryElectrically Erasable Programmable Read Only memory
(EEPROM),
Erasable Programmable Read Only memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
HO2SHeated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdol Air ControlIdol Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel±Shutoff±

± INTRODUCTIONTERMS FOR MANUAL TRANSAXLE REPAIR MANUAL
01±7
C250 M/T REPAIR MANUAL (RM1020E) ISC
Idle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass±
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range±
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree±Way Catalytic ConverterThree±Way Catalytic (TWC)
CC
RO
TWC+OCThree±Way + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle

C80543
C80544
SST
C68516
C68012
C68013
41±50
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
10. REMOVE 1ST GEAR
(a) Using 2 screwdrivers and a hammer, remove the clutch
hub No.1 shaft snap ring from the output shaft.
HINT:
Using a shop rug to prevent the shaft snap ring from being
scatted.
(b) Using SST and a press, remove the clutch hub No.1 assy
and 1st gear from the output shaft.
SST 09950±00020
11. REMOVE SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Remove the synchronizer ring No.1 from the 1st gear.
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
13. REMOVE 1ST GEAR THRUST WASHER
(a) Remove the 1st gear thrust washer from the output shaft.

C68021
C68022
C68409
C68240
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±53
C250 M/T REPAIR MANUAL (RM1020E)
21. INSPECT SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Coat the 1st gear cone with gear oil. Check the braking
effect of the synchronizer ring. Turn the synchronizer ring
in one direction while pushing it to the gear cone. Check
that the ring locks.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.75 ± 1.65 mm (0.0295 ± 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
22. INSPECT REVERSE GEAR
(a) Using a vernier caliper, measure the clearance between
the reverse gear and shift fork.
Maximum clearance: 0.35 mm (0.014 in.)
If the clearance exceeds the maximum, replace the shift form
or reverse gear.
23. INSPECT TRANSMISSION CLUTCH HUB NO.1
(a) Check that the transmission clutch hub No.1 and reverse
gear slides smoothly.
(b) Check that the spline gear's edges of the reverse gear is
not worn down.

C68241
C68014
C68013
C68012
C68310
41±54
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
24. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil, install it to the trans-
mission clutch hub No.1.
HINT:
Do not set the reverse gear and transmission clutch hub No.1
in incorrect orientation.
(b) Install the 3 synchromesh shifting key springs and 3 syn-
chromesh shifting keys.
25. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
(a) Coat the 1st gear thrust washer pin or ball with gear oil,
install it to the output shaft.
26. INSTALL 1ST GEAR THRUST WASHER
(a) Coat the 1st gear thrust washer with gear oil, install it to
the output shaft.
27. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil, install
it to the output shaft.
28. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil, install it to the output shaft.

C68311
C80547
SST
C68244
C68246
D30552
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±55
C250 M/T REPAIR MANUAL (RM1020E)
29. INSTALL SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.1 with gear oil, install it to
the 1st gear.
30. INSTALL TRANSMISSION CLUTCH HUB NO.1
(a) Using SST and a press, install the transmission clutch
hub No.1 to the output shaft
SST 09316±60011 (09316±00031)
HINT:

The 1st gear can be turned.

While checking the 1st gear thrust washer pin or ball is in-
serted into the groove of the 1st gear thrust washer, press
and fit the clutch hub No.1.
(b) Select a snap ring that will allow the minimum axial play.
Standard clearance:
0.1 mm (0.039 in.) or less
MarkThickness mm (in.)MarkThickness mm (in.)
A2.50 (0.0984)D2.68 (0.1055)
B2.56 (0.1008)E2.74 (0.1079)
C2.62 (0.1031)F2.80 (0.1102)
(c) Using brass bar and hammer, install the snap ring to the
output shaft.
31. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing and 2nd gear
bearing spacer with gear oil, install them to the output
shaft.
32. INSTALL SYNCHRONIZER RING NO.1 (FOR SECOND
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.1 with gear oil, install it to
the 2nd gear.