1999 TOYOTA AVENSIS brake

SERVICE SPECIFICATIONS
STANDARD BOLT SS–1. . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE (E251) SS–4. . . . . . . . . . . . .
SUSPENSION AND AXLE SS–9. . . . . . . . . . . . . . . .
BRAKE SS–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING SS–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM SS–15. . .
BODY ELECTRICAL SS–16. . . . . . . . . . . . . . . . . . . . .
BODY SS–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING SS–19. . . . . . . . . . . . . . . . . . . . .
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. RM599E)
NOTE: The above pages contain only the points which differ
from the above listed manual.

SS14B–01
– SERVICE SPECIFICATIONSBRAKE
SS–11
BRAKE
SERVICE DATA
Vacuum Pump
(1CD–FTV)Blade Minimum height
Minimum width
Minimum length16.20 mm (0.6378 in.)
5.95 mm (0.2343 in.)
44.96 mm (1.7701 in.)

SS0FT–04
SS–12
– SERVICE SPECIFICATIONSBRAKE
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Brake pedal x Brake pedal bracket36.837527
End cover x Casing7.88068 in.·lbf
Check valve x End cover7475054
Union x Check valve1414010
Vacuum pump x Engine2121415

MX09C–01
D06624
Air Cleaner Case
Assembly
with Air Hose
Air Flow Meter
Connector
D06625
Shift Lever Assembly
12 (120, 9)
Transmission Control Cable Bracket
Clip
WasherShift Cable Grommet
Retainer Shift Cable Grommet Select Control Cable
Shift Control CableConsole Box Assembly
Shift Lever Knob
Clip
Clip
Washer
WasherClip Front Ash Receptacle
Parking Brake Cover
Cap Cap
Air Duct
4.9 (50, 43 in.·lbf)Clip
4.9 (50, 43 in.·lbf)
N·m (kgf·cm, ft·lbf): Specified torque MX–48
– MANUAL TRANSAXLE (E251)SHIFT LEVER AND CONTROL CABLE
SHIFT LEVER AND CONTROL CABLE
COMPONENTS

SA10A–02
FA1535
SST
F02688
F02721
F02724
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–3
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608–16042 (09608–02021, 09608–02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serration on the drive shaft.
1. REMOVE FRONT WHEEL
2. DRAIN OUT GEAR OIL
3. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
4. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See Pub. No. RM599E on page SA–11)
6. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See Pub. No. RM599E on page
SA–11)
7. DISCONNECT DRIVE SHAFT FROM AXLE HUB
(a) Using a plastic hammer, disconnect the drive shaft from
the axle hub.
NOTICE:
Cover the drive shaft boot and ABS speed sensor rotor with
cloth to protect it from being damaged.
(b) Push the front axle hub toward the outside of the vehicle
to separate the drive shaft from the axle hub.
8. REMOVE DRIVE SHAFTS
(a) RH drive shaft:
Remove the 2 bolts and pull out the drive shaft together
with the center bearing bracket.

SA02Z–03
SA–10
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
INSTALLATION
1. LH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Install a new snap ring to the inboard joint shaft.
(b) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(c) Set the snap ring with opening side facing downward.
(d) Using a brass bar and hammer, install the drive shaft.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
HINT:
Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feel-
ing when driving it in.
(e) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction.
(f) Check that the drive shaft cannot be removed by hand.
2. RH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(b) Install the drive shaft with the center bearing bracket.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
(c) Install the 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
3. CONNECT DRIVE SHAFT TO AXLE HUB
NOTICE:
Be careful not to damage the boot and ABS speed sensor rotor.
4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
5. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle.
(b) Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
6. INSTALL DRIVE SHAFT LOCK NUT
(a) While applying brakes, install the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
(b) Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
7. w/ABS:
INSTALL ABS SPEED SENSOR AND BOLT
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
8. FILL AND CHECK GEAR OIL (See page MX–4)
9. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
10. CHECK FRONT WHEEL ALIGNMENT (See Pub. No. RM599E on page SA–4)
11. CHECK ABS SPEED SENSOR SIGNAL (See Pub. No. RM599E on page DI–115)

BRAKE
BRAKE PEDAL BR–1. . . . . . . . . . . . . . . . . . . . . . . . . .
VACUUM PUMP (1CD–FTV) BR–2. . . . . . . . . . . . . .
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. RM599E)
NOTE: The above pages contain only the points which differ
from the above listed manual.

BR11N–01
F08962
Brake PedalPedal PadReturn Spring
Cushion Plate Collar
Bushing Brake Pedal BracketStop Light Switch Clevis Pin
Clip
Stop Light Switch Connector

Bushing
: Specified torque
N·m (kgf·cm, ft·lbf)

Non–reusable part
Brake Pedal
Pedal Pad
Clevis Pin
Clip
Stop Light Switch
Stop Light Switch Connector
Brake Pedal Bracket

Bushing
Collar

BushingReturn SpringCushion Plate
Pedal Pad
Brake Pedal
Brake Pedal
Pedal Pad
Lithium soap base glycol grease
RHD M/T
A/T
LHD M/T
A/T
36.8 (375, 27)
36.8 (375, 27)
– BRAKEBRAKE PEDAL
BR–1
BRAKE PEDAL
COMPONENTS