2005 TOYOTA AVENSIS drive shaft

01±10
± INTRODUCTIONTERMS
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)Abbreviations Meaning
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PTCPositive Temperature Coefficient
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRSRigid Rear Suspension
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TFTToyota Free±Tronic

A14289
A13861
A01178
A01179
A13851
± ENGINE MECHANICALCYLINDER BLOCK ASSY
14±55
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
5. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
6. REMOVE PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 to 90 C (176 to 194 F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Store the pistons, pins, rings, connecting rods and bear-
ings in correct order so that they can be returned to the
original locations when re±assembling.
7. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.040 to 0.240 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
(b) If the thrust clearance is greater than maximum, replace
the thrust washers as a set.
Thrust washer thickness:
1.930 to 1.980 mm (0.0760 to 0.0780 in.)

B10446
B10014
B10015
B10452ContinuityOhmmeter
B10453
Ohmmeter
No Continuity 19±10
± STARTING & CHARGINGGENERATOR ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(b) Using a screwdriver, pry out the stator sub±assy genera-
tor w/rectifire.
4. REMOVE BEARING SET GENERATOR
5. REMOVE PULLEY SET GENERATOR
(a) Clamp the swivel arm in a vise.
NOTICE:
Be careful not to damage the fan.
(b) Using an impact wrench or internal serration on rotor shaft
end together with a torque wrench,remove the nut and
spring washer, then detach the pulley.
6. REMOVE GENERATOR ROTOR ASSY
(a) Using a press, press out the generator rotor assy and
spacer ring.
7. INSPECT GENERATOR ROTOR ASSY
(a) Inspect the generator rotor assy for open circuit.
(1) Using an ohmmeter, check that there is continuity
between the slip rings.
Standard resistance: 2.27 to 2.53
at 20
C (68
F)
If there is no continuity, replace the generator rotor assy.
(b) Inspect the generator rotor assy for ground.
(1) Using an ohmmeter, check that there is no continu-
ity between the slip ring and the generator rotor
assy.
If there is continuity, replace the generator rotor assy.

C80539
SST
C68005



C80431
C80541
D30552
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±49
C250 M/T REPAIR MANUAL (RM1020E)
5. REMOVE 4TH DRIVEN GEAR
(a) Using SST and a press, remove the output shaft bearing
rear and 4th driven gear from the output shaft.
SST 09950±00020
6. REMOVE OUTPUT GEAR SPACER
(a) Remove the output gear spacer from the output shaft.
7. REMOVE 2ND GEAR
(a) Using SST, remove the 3rd driven gear and 2nd gear from
the out put shaft.
SST 09950±00020
8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing and 2nd gear
bearing spacer from the output shaft.
9. REMOVE SYNCHRONIZER RING NO.1 (FOR SECOND
SYNCHRONIZER RING)
(a) Remove the synchronizer ring No.1 from the output shaft.

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.

C68248
C80548
SST
C68005
C82013
SST
C82014
SST
41±56
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
33. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil, install it to the output
shaft.
34. INSTALL 3RD DRIVEN GEAR
(a) Using SST and a press, install the 3rd driven gear to the
output shaft.
SST 09950±00020
35. INSTALL OUTPUT GEAR SPACER
(a) Install the output gear spacer to the output shaft.
36. INSTALL 4TH DRIVEN GEAR
(a) Using SST and a press, 4th driven gear to the output
shaft.
SST 09612±22011
37. INSTALL OUTPUT SHAFT REAR BEARING
(a) Using SST and a press, install the output shaft rear bear-
ing to the output shaft.
SST 09612±22011

410DG±01
D30520
Apply MP grease
1st Gear Thrust Washer Pin Or Ball
Output Shaft
1st Gear Needle Roller Bearing
1st Gear Thrust Washer
1st Gear
Reverse Gear
Synchronizer Ring No.1 (For 1st)
Synchromesh Shifting Key No.1
Synchromesh Shifting Key Spring No.1
Synchronizer Ring No.1 (For 2nd)
Clutch Hub No.1
Shaft Snap Ring
Transmission Clutch Hub No.1
2nd Gear Bearing Spacer
2nd Gear Needle Roller Bearing
2nd Gear
3rd Driven Gear
Output Gear Spacer
4th Driver Gear
Output Shaft Rear Bearing
x3
x3
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±47
C250 M/T REPAIR MANUAL (RM1020E)
OUTPUT SHAFT ASSY (C250)
COMPONENTS

C80559
Q04983
SST
C80560
C80561
C67821
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±39
C250 M/T REPAIR MANUAL (RM1020E)
5. REMOVE 4TH GEAR
(a) Using 2 screwdrivers and a hammer, remove the input
shaft rear bearing shaft snap ring from input shaft.
(b) Using SST and a press, remove the input shaft radial ball
bearing rear and 4th gear from input shaft.
NOTICE:
Do not tighten SST excessively.
SST 09950±00020
6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 4th gear needle roller bearing and 4th gear
bearing spacer from input shaft.
7. REMOVE SYNCHRONIZER RING NO.2 (FOR FOURTH
SYNCHRONIZER RING)
(a) Remove synchronizer ring No.2 from transmission clutch
hub No.2.
8. REMOVE 3RD GEAR
(a) Using 2 screwdrivers and a hammer, remove the clutch
hub No.2 setting shaft snap ring from the input shaft.
NOTICE:
Using a shop rug to prevent the snap ring from being scat-
tered.