2005 TOYOTA AVENSIS clutch

A64005
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±31
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE GENERATOR ASSY (See page 19±7)
41. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

Secure the compressor and hoses off to the side instead of discharging the A/C system.

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
42. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and the column hole cover silencer sheet.
43.SEPARATE STEERING INTERMEDIATE SHAFT (See page 50±9)
44.REMOVE FRONT DOOR SCUFF PLATE RH (See page 71±11)
45.REMOVE COWL SIDE TRIM BOARD RH (See page 71±11)
46. REMOVE FRONT FLOOR FOOTREST
47. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and the floor panel brace front.
48.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±2)
49.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09930±00010
50. REMOVE FRONT AXLE HUB RH NUT SST 09930±00010
HINT:
Perform the same procedure as above on the opposite side.
51.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6)
SST 09628±62011
52. SEPARATE TIE ROD END SUB±ASSY RH SST 09628±62011
HINT:
Perform the same procedure as above on the opposite side.
53.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
54. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
55.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
56. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
57.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
58. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts and 2 nuts, and detach the enginemounting insulator.

A76718
A76719
A62838SST
A62838SST
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±33
AVENSIS REPAIR MANUAL (RM1018E)
60. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Remove the through bolt and nut, detach the engine
mounting insulator FR from the engine mounting bracket.
(b) Remove the through bolt, detach the engine mounting in- sulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the suspension crossmember and the engine mounting
member.
61.REMOVE STARTER ASSY(See page 19±3)
62.REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page 41±15)
63.REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
64.REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42±26)
65.REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) 66. REMOVE FLYWHEEL SUB±ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and theflywheel.
SST 09960±10010 (09962±01000, 09963±01000)
67. REMOVE DRIVE PLATE & RING GEAR SUB±ASSY (A/T TRANSAXLE)
(a) Hold the crankshaft with SST, remove the 8 bolts and the
drive plate & ring gear.
SST 09960±10010 (09962±01000, 09963±01000)
68. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.

A62204
1
5
3
82
6
4
7
A76719
A76718
A76717
14±42
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Clean the bolt and bolt hole.
(c) Apply adhesive to the bolts. Adhesive:
Part No. 09330±00070, THREE BOND or equivalent.
(d) Using several steps, install and tighten the 8 bolts uni- formly in the sequence shown in the illustration.
Torque: 88 N
m (897 kgf
cm, 65 ft
lbf)
115.INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
116.INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)(See page 42±26) SST 09301±00210
117.INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)(See page 41±15)
118.INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page 40±11)
119.INSTALL STARTER ASSY(See page 19±3)
120. INS TALL FRO NT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen- sion crossmember and the engine mounting member.
(b) Install the bolt which is used to secure the rear engine
mounting bracket to the mounting insulator.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(c) Install the bolt which is used to secure the front engine mounting bracket to the mounting insulator.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
121. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670±00010
(a) Set the engine assembly with transaxle on the engine lift- er.
(b) Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N
m (816 kgf
cm, 59 ft
lbf)
(d) Install the engine mounting insulator RH. Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)

A76717
A
B
A
B
A76716
AA
BBBBBB
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±43
AVENSIS REPAIR MANUAL (RM1018E)
(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 N
m (459 kgf
cm, 33 ft
lbf) for Bolt A
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Nut B
(f) Install the front suspension member brace LH and RH with the 8 bolts.
Torque:
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Bolt A
80 N
m (816 kgf
cm, 59 ft
lbf) for Bolt B
NOTICE:
When installing the crossmember, check that the position-
ing holes on the crossmember and on the vehicle are
aligned with each other.
122.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
123. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
124.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
125. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
127. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
128.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
129. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
130.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±2)
131. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
132.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
133.INSTALL GENERATOR ASSY (See page 19±7)
134. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
135. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
136. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)

A76703
Fan and Generator V Belt
Cooler Compressor Assy
N´m (kgf´cm, ft´lbf) : Specified torque
29 (296, 21)
A/T:
Floor Shift Transmission
Control Cable Assy Clip
Clutch Release Cylinder Assy
Floor Shift Cable Transmission
Control Shift
Floor Shift Cable Transmission
Control Select
Clip
Clip
25 (255, 18)
12 (122, 9)
25 (255, 18)
12 (122, 9)
54 (551, 40)
25 (255, 18)
Generator Assy Terminal Cap
No. 19.8 (100, 7)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±21
AVENSIS REPAIR MANUAL (RM1018E)

A79349N´m (kgf´cm, ft´lbf): Specified torqueAutomatic Transaxle Assy
Drive Plate Spacer
RR
Drive Plate & Ring Gear Sub±assy
Drive Plate Spacer
FR
A/T:
28 (286, 21)
88 (897, 65)
Clutch Disk Assy
Clutch Cover Assy
Manual Transaxle Assy
Starter Assy
Flywheel Sub±assy
See page 14±27
1st 49 (500, 36)
2nd Turn 90

37 (377, 27)
37 (377, 27)
64 (653, 47)
19 (194, 14)
64 (653, 47)
9.8 (100, 7)
47 (479, 35)
47 (479, 35)
14±24
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

141BF±01
A77281
A77301
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.

A77298
LHD Steering Position typeRHD Steering Position type
14±124
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE FRONT AXLE HUB RH NUT SST09330±00030
HINT:
Perform the same procedure as above on the opposite side.
41.SEPARATE TIE ROD END SUB±ASSY LH (See page 51±36)
42.SEPARATE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
43.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
44.SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
(See page 26±21)
46.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) (See page 26±16)
47.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
48.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
49.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
50.SEPARATE FRONT AXLE ASSY RH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side. 51.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
(a)Remove 7 bolts as shown in the illustration.
52.SEPARATE TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
53.SEPARATE TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
54. SEPARATE ACCELERATOR CONTROL CABLE ASSY