2005 TOYOTA AVENSIS clutch

1302Z−04
A77123
SST
A60595E2 VC
13−6− INTAKETURBO CHARGER SYSTEM (1CD−FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
ON−VEHICLE INSPECTION
1. INSPECT INTAKE AIR SYSTEM
(a) Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between
the turbocharger outlet and cylinder head.
ConditionOperation
Clogged air cleanerClean or replace the element
Collapsed or deformed hosesRepair or replace
Leakage from connectionsCheck each connection and repair
Cracks in componentsCheck and replace
2. INSPECT EXHAUST SYSTEM
(a) Check for leakage or clogging between the cylinder head and turbocharger inlet and between the
turbocharger outlet and exhaust pipe.
ConditionOperation
Deformed componentsRepair or replace
Foreign material in passagesRemove
Leakage from componentsRepair or replace
Cracks in componentsCheck and replace
3. CHECK TURBOCHARGING PRESSURE
(a) Warm up the engine.
(b) Using a 3−way connector, connect SST (turbocharger
pressure gauge) to the hose leading to the intake air con-
nector.
SST 09992−00242
(c) While depressing the clutch pedal, press the accelerator
pedal down fully. Measure the turbocharging pressure at
the maximum speed (5,100 to 5,250 rpm).
Standard pressure:
15 to 45 kPa (0.15 to 0.46 kgf/cm
2, 2.2 to 6.5 psi)
If the pressure is less than specification, check both the intake
air and exhaust systems for leakage.
If there is no leakage, check if the actuator hose has discon-
nected. If not, check the turbocharger.
If the pressure is greater than the specification, check if the ac-
tuator hose has disconnected or cracked. If not, check the
turbocharger.
4. INSPECT TURBO PRESSURE SENSOR
(a) Inspect the power source voltage.
(1) Disconnect the turbo pressure sensor connector.
(2) Turn the ignition switch to ON.
(3) Using a voltmeter, measure the voltage between
connector terminals 3 (VC) and 1 (E2) of the wire
harness side.
Voltage: 4.5 to 5.5 V
If the result is not as specified, check the wiring and ECM.

A79140
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 1
AVENSIS Supplement (RM1045E)
30. REMOVE CLUTCH ACCUMULATOR ASSY (See Pub. No. RM1018E on page 42 −22)
SST 09023 −00100
31. REMOVE CLUTCH RELEASE CYLINDER ASSY (See Pub. No. RM1018E on page 42 −17)
32. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
33. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(See Pub. No. RM1018E on page 55 −86)
HINT:
Secure the hoses off to the side instead of detaching.
34. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
35. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
36. SEPARATE RETURN TUBE SUB −ASSY
(a) Remove the 2 clamp bolts, then separate the return tube
sub−assembly.
37. SEPARATE VANE PUMP OIL RESERVOIR ASSY
38. REMOVE FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30 −6)
SST 09930 −00010
HINT:
Perform the same procedure as above on the opposite side.
39. SEPARATE TIE ROD END SUB −ASSY LH (See Pub. No. RM1018E on page 30 −6)
SST 09628 −62011
HINT:
Perform the same procedure as above on the opposite side.
40. SEPARATE FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
41. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and column hole cover silencer sheet.
42. REMOVE STEERING COLUMN HOLE COVER SUB −ASSY NO.1
43. REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See Pub. No. RM1018E on page 51 −36)
44. SEPARATE FRONT SUSPENSION ARM SUB −ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
45. SEPARATE FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.

A85927
Engine Hanger No. 1 Upper
Engine Hanger No. 2
Engine Hanger No. 1
A61175
A62711
A79180
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)14−11 3
AVENSIS Supplement (RM1045E)
(h) Install the 2 engine hangers with the 2 bolts.
Part No.:
No. 1 engine hanger upper (yellow) 12284−27020
No. 1 engine hanger upper (black) 12284−27030
No. 1 engine hanger 12281−27050
No. 2 engine hanger 12282−27060
Bolt 91642−81025
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
(i) Attach the engine sling, then hang the engine with the
chain block.
47. REMOVE POWER STEERING IDLE PULLEY
BRACKET
(a) Remove the 3 bolts and power steering idle pulley brack-
et.
48. REMOVE FRONT SUSPENSION CROSSMEMBER
SUB−ASSY
(a) Remove the through bolt and nut, then detach the engine
mounting insulator front from the engine mounting brack-
et.
(b) Remove the through bolt, then detach the engine mount-
ing insulator rear from the suspension crossmember.
(c) Separate the engine together with the transaxle from the
suspension crossmember and engine mounting member.
49. REMOVE STARTER ASSY (See Pub. No. RM1018E on page 19−24)
50. REMOVE MANUAL TRANSAXLE (See Pub. No. RM1018E on page 41−33)
51. REMOVE CLUTCH COVER ASSY (See Pub. No. RM1018E on page 42−26)
52. REMOVE CLUTCH DISC ASSY (See Pub. No. RM1018E on page 42−26)

A79183
2
1
3
4
5
6
7
8
A79180
A62711
A61175
BA
A 14−130
− ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(d) Using a Torx socket wrench (T55), uniformly install and
tighten the 8 Torx screws in several steps in the sequence
shown in the illustration.
Torque: 71 N
m (720 kgf
cm, 52 ft
lbf)
184. INSTALL CLUTCH DISC ASSY (See Pub. No. RM1018E on page 42−26)
SST 09301−00210
185. INSTALL CLUTCH COVER ASSY (See Pub. No. RM1018E on page 42−26)
186. INSTALL MANUAL TRANSAXLE (See Pub. No. RM1018E on page 41−33)
187. INSTALL STARTER ASSY (See Pub. No. RM1018E on page 19−24)
188. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB−ASSY
(a) Attach the engine together with the transaxle to the sus-
pension crossmember and engine mounting member.
(b) Install the bolt which secures the rear engine mounting
bracket to the mounting insulator.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(c) Install the bolt which secures the front engine mounting
bracket to the mounting insulator.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
189. I N S TA L L P O W E R S T E E R I N G I D L E P U L L E Y
BRACKET
(a) Install the power steering idle pulley bracket with the 3
bolts.
Torque:
72 N
m (734 kgf
cm, 53 ft
lbf) for bolt A
39 N
m (398 kgf
cm, 29 ft
lbf) for bolt B
190. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine together with the transaxle on the engine
lifter.

A93403
2to7mm
(0.0787 to
0.2756 in.)0to4mm
(0 to
0.1575 in.)
Intake Shutter Side:
Air Hose No. 3 Side:
4to12mm
(0.1575 to
0.4724 in.)
14
−132
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
191. INSTALL FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
192. INSTALL FRONT SUSPENSION ARM SUB −ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
193. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2
(See Pub. No. RM1018E on page 51 −36)
194. INSTALL FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
195. INSTALL TIE ROD END SUB −ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
196. INSTALL FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
197. INSTALL RETURN TUBE SUB −ASSY
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
198. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
199. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
200. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See Pub. No. RM1018E on page 55 −86)
201. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
202. INSTALL CLUTCH RELEASE CYLINDER ASSY (See Pub. No. RM1018E on page 42 −17)
203. INSTALL CLUTCH ACCUMULATOR ASSY (See Pub. No. RM1018E on page 42 −22)
SST 09023 −00100
204. INSTALL AIR TUBE NO.2
(a) Install the air hose and 2 hose clamps as shown in the il-lustration.

A87967
Upward90_
Clamp
Bolt
Turbocharger Side:
Air Hose No. 2 Side:
Front 90
_ Clamp Bolt
20.4_
14
−134
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(b) Tighten the 2 hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
208. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
209. INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See Pub. No. RM1018E on page 16 −51)
210. INSTALL ENGINE ROOM RELAY BLOCK NO.3
Torque: 5.3 N
m (54 kgf
cm, 47 in.
lbf)
211. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
212. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
213. INSTALL BATTERY Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt
3.0 to 4.0 N
m (31 to 41 kgf
cm, 27 to 35 in.
lbf) for nut
5.4 N
m (55 kgf
cm, 48 in.
lbf) for terminal
214. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
215. BLEED CLUTCH PIPE LINE (See Pub. No. RM1018E on page 42 −12)
216. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
217. ADD MANUAL TRANSAXLE OIL (See Pub. No. RM1018E on page 41 −5)
218. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
219. ADD ENGINE COOLANT (See page 16 −19)
220. CHECK CLUTCH FLUID LEAKAGE
221. CHECK FLUID LEVEL IN RESERVOIR
222. CHECK BRAKE FLUID LEAKAGE
223. CHECK FOR ENGINE OIL LEAKS
224. CHECK FOR FUEL LEAKS (See page 11 −46)
225. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
226. CHECK FOR EXHAUST GAS LEAKS
227. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See Pub. No. RM1018E on page 26 −6)

A93086N·m (kgf·cm, ft·lbf)
: Specified torque
19 (194, 14)
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Battery Carrier
5.0 (51, 44 in.
lbf)
29 (296, 21)
x4
52 (530, 38)
21 (214, 16)
5.0 (51, 44 in.
lbf)
13 (133, 10)x4
Battery Tray
Battery
Battery Clamp
12 (122, 8.9)
Radiator Relay
Block
Clip
Transmission Control Cable
7.0 (71, 62 in.
lbf)
Compressor and
Magnetic Clutch
Generator Assy
9.8 (100, 7.2)
Radiator Assy
Radiator Hose Inlet
Cooler Refrigerant Suction Hose No. 1
(LHD Steering Position Type)
Union to Connector Tube Hose
Charcoal Canister Assy
x2Radiator Hose Outlet
Cooler Refrigerant Suction Hose No. 1
(RHD Steering Position Type)
3.5 (36, 31 in.
lbf)
5.0 (51, 44 in.
lbf)
x3
14−12
− ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)

400H3−02
D26429
D03701
Snap Ring
D26430
Underdrive
Clutch Drum
40−94
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while ap-
plying and releasing compressed air (392 kPa, 4.0 kgf/
cm
2, 57 psi).
Pack clearance:1.51−1.71mm (0.0594−0.0673 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the under-
drive clutch drum.