1999 TOYOTA AVENSIS Supplement

MX096–02
D06619
Starter
39 (400, 29)
Clutch Release
Cylinder
and Line
12 (120, 9)
4.9 (50, 43 in.·lbf)
12 (120, 9)
Control CableClip
Clip
Washer Air Flow Meter
ConnectorAir Cleaner Case
Assembly
with Air Hose
52 (530, 38)
87 (890, 64)
Engine Left
Mounting Bracket
Battery
Tray
No.1 Air Tube Assembly
Diesel Throttle Body
with No.2 Air Tube Assembly
Stay
VSV Connector for EGR
Turbo Pressure
Sensor Connector
Intake Air Temperature
Sensor Connector
Throttle Full
Switch Connector
Throttle Control
Motor Connector

Gasket

Non–reusable part
21 (214, 15)
N·m (kgf·cm, ft·lbf): Specified torque
15 (153, 11)
25 (255, 18)
25 (255, 18)
25 (255, 18)
25 (255, 18)
MX–2
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MANUAL TRANSAXLE UNIT
COMPONENTS

D06618
RH Drive Shaft
LH Drive
Shaft
216 (2,200, 159)
Lock Nut Cap

Cotter Pin
Snap Ring
Front Exhaust Pipe
Engine Mounting
Center Member
LH Engine Under Cover RH Engine Under Cover
64 (650, 47)
Transaxle Case
Protector
25 (250, 18)
Back–Up Light
Switch Connector
Speed Sensor
Connector
Front Transport
HookHole Plug
Hole PlugHole Cover
64 (650, 47)
39 (400, 29)
73 (740, 54)
73 (740, 54)
52 (540, 38)
Tie Rod End
Engine Rear
Mounting Bracket
64 (650, 47)
98 (1,000, 72)
29 (300, 22)
64 (650, 47)
49 (500, 36)
127 (1,300, 94)
Ground Cable
Engine Front
Mounting Bracket
Engine Front
Mounting
Suction Pipe
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
Gasket
Gasket
8.0 (82, 71in.·lbf)
40 (408, 30)
x 10Bolt with Spring
20 (204, 15)
46 (470, 34)
62 (630, 46)
48 (490, 35)
40 (408, 30)
87 (890, 64)
64 (650, 47)
x 10
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MX–3

MX097–02
D06626
(a)(b)
D06627
D06628
MX–4
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
3. REMOVE LH AND RH ENGINE UNDER COVERS
4. REMOVE NO.1 AIR TUBE ASSEMBLY
(a) Disconnect the No.2 vacuum hose from the E–VRV for
EGR.
(b) Disconnect the No.2 vacuum hose from the VSV for EGR.
(c) Disconnect the VSV connector for EGR.
(d) Disconnect the turbo pressure sensor connector and vac-
uum hose.
(e) Remove the 2 bolts as shown in the illustration.
Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)
(f) Disconnect the 2 hose clips, and remove the No.1 air tube
assembly.
5. REMOVE DIESEL THROTTLE BODY WITH NO.2 AIR
TUBE ASSEMBLY
(a) Disconnect the intake air temperature sensor connector.
(b) Disconnect the throttle control motor connector.
(c) Disconnect the full opener switch connector.
(d) Remove the 3 bolts from the diesel throttle body.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
(e) Remove the 2 bolts as shown in the illustration.
Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)
(f) Disconnect the 2 hose clips, and remove the diesel
throttle body assembly with the No.2 air tube assembly.

D06629
D06639
A
B
D06633
D06636
B AA
D06634
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MX–5
6. REMOVE STARTER
(a) Remove the 2 bolts and disconnect the radiator reservoir
from the radiator.
(b) Disconnect the starter connector.
(c) Remove the nut, and disconnect the starter wire.
Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)
(d) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
7. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts and disconnect the release cylinder
and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
8. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
9. DISCONNECT VEHICLE SPEED SENSOR AND
BACK–UP LIGHT SWITCH CONNECTORS
10. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
11. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 29 N·m (296 kgf·cm, 21 ft·lbf)
12. INSTALL ENGINE SUPPORT FIXTURE
Install the engine hanger in the correct direction.
Parts No.:
Engine hanger: 12281–27010
Bolt: 96122–61020
Torque: 37 N·m (377 kgf·cm, 27 ft·lbf)

D06632AB
D06638
Q10165
Filler Plug
Oil Level
0 – 5 mm
Drain Plug
D06631
MX–6
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
13. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET
BOLTS AND NUT
Torque:
Bolt A: 52 N·m (530 kgf·cm, 38 ft·lbf)
Nut B: 87 N·m (890 kgf·cm, 64 ft·lbf)
14. REMOVE ENGINE LEFT MOUNTING BRACKET
Lower the transaxle side and remove the bolt and bracket.
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
15. REMOVE FRONT WHEEL
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
16. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
17. DRAIN TRANSAXLE OIL
Oil grade: API GL–4 or GL–5
Viscosity: SAE 75W–90
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
18. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, 2 nuts and gasket from the exhaust
manifold.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Remove the 2 bolts, 2 springs, gasket and pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
19. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA–1)
20. REMOVE ENGINE MOUNTING CENTER MEMBER
(a) Remove the 2 bolts and front transport hook.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Support the suspension crossmember with a jack.
(c) Remove the nuts, and disconnect the suction pipe.

D06630
A
A
B
D02167
A
B
D06635
D06637
A
B
CED
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MX–7
(d) Remove the 2 hole plugs and hole cover.
(e) Remove the 7 bolts and center member.
Torque:
Bolt A: 73 N·m (740 kgf·cm, 54 ft·lbf)
Bolt B: 52 N·m (540 kgf·cm, 38 ft·lbf)
21. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
22. REMOVE ENGINE REAR MOUNTING BRACKET
Remove the 4 bolts and bracket.
Torque:
Bolt A: 98 N·m (1,000 kgf·cm, 72 ft·lbf)
Bolt B: 64 N·m (650 kgf·cm, 47 ft·lbf)
23. REMOVE ENGINE FRONT MOUNT AND MOUNTING
BRACKET
(a) Remove the bolt and nut.
Torque: 87 N·m (890 kgf·cm, 64 ft·lbf)
(b) Remove the 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
24. REMOVE TRANSAXLE LOWER SIDE MOUNTING
BOLT
Remove the 5 bolts.
Torque:
Bolt A: 40 N·m (408 kgf·cm, 30 ft·lbf)
Bolt B: 40 N·m (408 kgf·cm, 30 ft·lbf)
Bolt C: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
Bolt D: 20 N·m (204 kgf·cm, 15 ft·lbf)
Bolt E: 46 N·m (470 kgf·cm, 34 ft·lbf)
25. REMOVE TRANSAXLE
Lower engine left side and remove the transaxle from the en-
gine.
HINT:
At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the
transaxle to the engine.
Temporarily tighten the transaxle mounting bolts.
26. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

MX05P–02
MX–8
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
INSTALLATION
Installation is in the reverse order of removal.
(See page MX–4)
HINT:
After installation, check and inspect items as follows.
Front wheel alignment (See Pub. No. RM599E, page SA–4).
Do the road test.

MX098–01
D06620
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Lever Housing
Support Bracket
Boot
Clutch Release
Line Bracket
Transaxle Case
Transmission
Oil Cooler
Sub–AssemblyElbow

O–Ring Vehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
PipeMagnet
Transmission
Oil Pipe

Output Shaft Cover
Tapered Roller Bearing
Outer Race

Front Oil Seal
Input Shaft Front
BearingTransmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
17 (175, 13)
47 (480, 35)
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
Gasket



17 (175, 13)
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–9
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS