1999 TOYOTA AVENSIS clutch

MX02F–03
Q06204
Front
Q06205
SST Align the holes
Z00225
Q06206
SST
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
MX–35
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to the front of the
transmission.
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506–35010
HINT:
Align the hole of the output shaft and inner race.
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316–60011 (09316–00041)
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX–31)

Q06314
MT0792
N00495
Z00390
Z00391
SST MX–36
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
5. INSTALL BALL AND INNER RACE TO OUTPUT SHAFT
HINT:
Align the groove of the inner race and ball.
6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-
CHRONIZER RING, 2ND GEAR AND 3RD DRIVEN
GEAR
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearing.
(c) Place the synchronizer rings (for the 2nd gear) on the
gear.
NOTICE:
Do not install the synchronizer ring for the 1st gear.
(d) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
7. MEASURE 2ND GEAR THRUST CLEARANCE
(See page MX–31)
8. INSTALL SPACER AND 4TH DRIVEN GEAR
(a) Install the spacer.
(b) Using a press, install the 4th driven gear.
9. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 09506–30012

AIR CONDITIONING
DRIVE BELT (1CD–FTV) AC–1. . . . . . . . . . . . . . . . . .
MANIFOLD GAUGE SET (1CD–FTV) AC–4. . . . . . .
REFRIGERANT LINE AC–6. . . . . . . . . . . . . . . . . . . . .
COMBUSTION TYPE POWER HEATER AC–9. . . .
ELECTRICAL TYPE POWER HEATER AC–23. . . . .
COMPRESSOR AND MAGNETIC CLUTCH
(1CD–FTV) AC–25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY (1CD–FTV) AC–29. . . . . . . . . . . . . . . . . . . . . . .
CONDENSER FAN (1CD–FTV) AC–30. . . . . . . . . . . .
WATER TEMPERATURE SWITCH
(1CD–FTV) AC–36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

AC2A9–01
I12482
3
I12483
1 2
– AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV)
AC–25
COMPRESSOR AND MAGNETIC
CLUTCH (1CD–FTV)
ON–VEHICLE INSPECTION
1. MAKE THESE VISUAL CHECKS:
(a) Leakage of grease from the clutch bearing
(b) Signs of oil on the pressure plate or rotor
2. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
(a) Start the engine.
(b) Check for abnormal noise from the compressor when the
A/C switch is OFF.
If abnormal noise is being emitted, replace the magnetic clutch.
3. INSPECT MAGNETIC CLUTCH OPERATION
(a) Disconnect the connector.
(b) Connect the positive (+) lead from the battery to the termi-
nal 3 on the magnetic clutch connector and the negative
(–) lead to the body ground.
(c) Check that the magnetic clutch is energized.
If operation is not as specified, replace the magnetic clutch.
4. INSPECT COMPRESSOR LOCK SENSOR RESIS-
TANCE
(a) Disconnect the connector.
(b) Measure resistance between terminals 1 and 2.
Standard resistance: 65 – 125 Ω at 20C (68F)

AC2AA–01
I12486
Suction Hose
Discharge Hose Spacer
 O–Ring
Engine Under Cover RH
10 (100,7)
25 (250, 18)
Drive Belt
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non–reusable part
I12495
Pressure Plate
Snap Ring
 Snap RingCompressor Stator
Shim
Rotor
13.2 (135, 9)
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non–reusable part AC–26
– AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV)
COMPONENTS

AC2AB–01
I12494
I12469
– AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV)
AC–27
REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR
APPROX. 10 MINUTES WITH A/C ON
2. STOP ENGINE
3. DISCONNECT NEGATIVE (–) TERMINAL CABLE
FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE DRIVE BELT
(See page AC–2)
7. DRAIN ENGINE COOLANT
8. REMOVE RESERVOIR TANK
(a) Remove the upper hose.
(b) Disconnect the lower hose.
(c) Disconnect the 2 bolts and reservoir tank.
9. DISCONNECT DISCHARGE AND SUCTION HOSES
Remove the 2 bolts and disconnect the both hoses.
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
10. REMOVE COMPRESSOR
(a) Disconnect the connector.
(b) Remove the 3 bolts and compressor.

AC2AC–01
I12469
I12494
AC–28
– AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV)
INSTALLATION
1. INSTALL COMPRESSOR
(a) Install the compressor with the 3 bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Connect the connector.
2. CONNECT DISCHARGE AND SUCTION HOSES
Connect the both hoses with the 2 bolts.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
CAUTION:
Hoses should be connected immediately after the caps
have removed.
HINT:
Lubricate 2 new O–rings with compressor oil and install the
hoses.
3. INSTALL RESERVOIR TANK
(a) Connect the reservoir tank with the 2 bolts.
(b) Connect the lower hose.
(c) Install the upper hose.
4. REFILL ENGINE COOLANT
5. INSTALL AND CHECK DRIVE BELT
(See page AC–3)
6. INSTALL ENGINE UNDER COVER RH
7. CONNECT NEGATIVE (–) TERMINAL CABLE TO BAT-
TERY
8. EVACUATE AIR IN REFRIGERATION SYSTEM AND
CHARGE WITH REFRIGERANT
Specified amount: 450
50 g (15.87
1.76 oz.)
9. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check the tightening torque at the
joints.
10. INSPECT A/C OPERATION

I12488
AC2AD–01
I12487
2 3
5 1
1 23 5
– AIR CONDITIONINGRELAY (1CD–FTV)
AC–29
RELAY (1CD–FTV)
INSPECTION
ELECTRICAL TYPE POWER HEATER
(a) Remove magnetic clutch relay (marking: HTR sub1,
sub2, sub3) from engine room relay block.
(b) Inspect magnetic clutch relay (marking: HTR sub1, sub2,
sub3) continuity.
ConditionTester connectionSpecified condition
Constant1 – 2Continuity
Apply B+ between
terminals 1 and 2.3 – 5Continuity
If continuity is not as specified, replace the relay.
(c) Reinstall relay to engine room relay block.