2005 TOYOTA AVENSIS hood release

030ND±02
± SERVICE SPECIFICATIONSMANUAL TRANSMISSION / TRANSAXLE
03±53
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
Floor shift transmission control cable assy x Body5.05144 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
FLOOR SHIFT SHIFT LEVER ASSY
Floor shift shift lever assy x Body121229
MANUAL TRANSAXLE ASSY (1ZZ±FE/ 3ZZ±FE)
Filler and drain plugs3940029
Engine hanger set bolt3838728
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
47
23650
480
23047
35
17
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Starter assy x Manual transaxle assy3738027
Starter wire set nut131309
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:
Bolt C:25
14
5.0250
141
2119
10
44 in.
lbf
Manual transaxle assy x Wire harness clmap Bolt A:
Bolt B:26
19260
19519
14
Manual transaxle assy x Ground cable Bolt A:
Bolt B:26
40260
41019
30
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head cover No.2 x Engine7.07162 in.
lbf
Hood set bolt1313310
MANUAL TRANSAXLE ASSY (1AZ±FE/ 1AZ±FSE)
Filler and drain plugs4950036
Engine hanger x Engine3838728
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Manual transaxle assy x Ground cable Bolt A:
Bolt C:26
40260
41019
30
Manual transaxle assy x Wire harness clamp8.48574 in.
lbf
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:9.0
1292
12080 in.
lbf
9

4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26

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

410DS±01
D30478
Battery Clamp Sub±assy
Battery Tray
Charcoal Canister Assy Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2
Starter AssyBack±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
ClipClip
37 (380, 27)
Starter Connector
Transverse Engine
Engine Mounting Insulator
52 (530, 38)
52 (530, 38)
Ground Cable
Gasket
7.0 (71, 62 in.
lbf)
Filler Plug
37 (380, 27)
23 (230, 17)
47 (479, 35)
N´m (kgf´cm, ft´lbf) : Specified torque
19 (195, 14)
13 (130, 9)
64 (653, 47)
64 (653, 47)
5.0 (51, 44 in.
lbf)

Non±reusable part
5.0 (51, 44 in.
lbf)
14 (141, 10)
13 (133, 10)
13 (131, 9)
5.0 (51, 44 in.
lbf)
26 (260, 19)
25 (255, 18)
80 (816, 59)
26 (260, 19)
23 (230, 17)
Engine Room Cover Side
Radiator Support Opening Cover
40 (410, 30)
39 (400, 29)
Manual Transaxle Assy
64 (653, 47)
Battery
Clutch Release Cylinder Assy
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS

B66980
B66983
B62438
B57767
± ENGINE HOOD/DOORREAR DOOR
75±25
AVENSIS REPAIR MANUAL (RM1018E)
(c) Remove the door lock link silencer.
13. REMOVE REAR DOOR GLASS SUB±ASSY LH
(a) Carefully pull up the door glass out of the door panel.
HINT:
Insert a shop rag inside the door panel to prevent the glass from being scratched.
14. REMOVE REAR DOOR WINDOW REGULATOR
SUB±ASSY LH
(a) w/ Power window:
Disconnect the window regulator connector.
(b) Remove the 4 bolts and window regulator.
NOTICE:
When the bolts are removed, the window regulator may fall
and become deformed.
HINT:
Remove the door window regulator through the service hole.
15. REMOVE REAR DOOR W/MOTOR LOCK ASSY LH
(a) Disconnect the door lock connector.
(b) Using a torx socket wrench (T30), remove the 3 screws
and door lock.
HINT:
Remove the door lock through the service hole.
(c) Remove the door lock wire harness packing.
16. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH
(a) Using a torx socket wrench (T30), loosen the screw.
(b) Remove the cover.
HINT:
Remove the cover through the service hole.
17. REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH
(a) Pull and hold the release plate of the handle frame as
shown in the illustration.

B56613
(1)
(2)
B68931
Screw
B68928
B68928
Adhesive
75±26
± ENGINE HOOD/DOORREAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the handle pushing and pulling it in the direction
indicated by the arrow mark in the illustration.
NOTICE:
If the release plate is not pulled and held when removing
the handle, the release plate will interfere with the handle
and become damaged .
(c) Remove the outside handle pads front and rear.
18. REMOVE REAR DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Using a torx socket wrench (T30), loosen the screw and
remove the frame.
19. REMOVE REAR DOOR CHECK ASSY LH
(a) Remove the 2 nuts, bolt and check.
HINT:
Remove the check through the service hole.
20. REMOVE REAR DOOR WEATHERSTRIP LH
(a) Using a clip remover, disengage the clip and remove the weatherstrip.
HINT:
If the clip is damaged, replace it with a new clip.
21. INSTALL REAR DOOR CHECK ASSY LH
(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 nuts.
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(c) Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(d) Install the check to the body panel with the bolt.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)

B68931
Screw
B57767
B64044
1 2
± ENGINE HOOD/DOORREAR DOOR
75±27
AVENSIS REPAIR MANUAL (RM1018E)
22. INSTALL REAR DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Apply MP grease to the sliding areas of the frame.
(b) Using a torx socket wrench (T30), install the handle frame
with the screw.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
NOTICE:
A cover should be inserted between the nut and the door
panel.
23. INSTALL REAR DOOR OUTSIDE HANDLE ASSY LH
(a) Install the outside handle pads front and rear.
(b) Pull and hold the release plate of the frame, as shown in
the illustration.
(c) Install the handle pushing it in the direction indicated by
arrow marks in the illustration.
NOTICE:
If the release plate is not pulled and held when installing the
handle, the release plate will interfere with the handle be-
come damaged .
24. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
(a) Using a torx socket wrench (T30), install the outside handle cover with the screw.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
25. INSTALL REAR DOOR W/MOTOR LOCK ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
door lock.
(b) Install a new door lock wire harness packing.
NOTICE:

When reusing a lock that has been removed, replace
the packing in the connecting part with a new one.

Be careful that grease or dirt does not stick to the
packing surface in the connecting part.

Reusing removed packing or using damaged packing
will allow water to penetrate through to the connect-
ing part resulting in a door lock malfunction.

B62438
Adhesive
Adhesive
B66982
w/ Power Window
w/o Power Window
B66983
75±28
± ENGINE HOOD/DOORREAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(c) Engage the door lock with the release plate of the handle,
and then set it to the door panel.
NOTICE:
Make sure that the release plate of the frame is securely en-
gaged with the door lock.
(d) Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(e) Using a torx socket wrench (T30), install the door lock with
the 3 screws.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(f) Connect the door lock connector.
26. INSTALL REAR DOOR WINDOW REGULATOR
SUB±ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
window regulator.
(b) Install the window regulator with the 4 bolts.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
NOTICE:
Be careful not to drop the window regulator as this may
cause deformation.
(c) Connect the window regulator connector.