1999 TOYOTA AVENSIS service

SS0ZS–01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess BoltStud Bolt Weld BoltClass
4T
5T
6T
7T
8T
9T
10T
11 T
No Mark
w/ WasherNo MarkNo Mark
w/ Washer
– SERVICE SPECIFICATIONSSTANDARD BOLT
SS–1
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH

SS0ZT–01
SS–2
– SERVICE SPECIFICATIONSSTANDARD BOLT
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHexagon flange boltmmmmN·mkgf·cmft·lbfN·mkgf·cmft·lbf
4T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 555
130
260
480
760
1,15048 in.·lbf
9
19
35
55
836
14
29
53
84
–60
145
290
540
850
–52 in.·lbf
10
21
39
61
–
5T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
14065
160
330
600
930
1,40056 in.·lbf
12
24
43
67
1017.5
17.5
36
65
100
–75
175
360
670
1,050
–65 in.·lbf
13
26
48
76
–
6T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
17080
195
400
730
1,100
1,75069 in.·lbf
14
29
53
80
1279
21
44
80
125
–90
210
440
810
1,250
–78 in.·lbf
15
32
59
90
–
7T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.510.5
25
52
95
145
23011 0
260
530
970
1,500
2,3008
19
38
70
108
16612
28
58
105
165
–120
290
590
1,050
1,700
–9
21
43
76
123
–
8T
8
10
121.25
1.25
1.2529
61
11 0300
620
1,10022
45
8033
68
120330
690
1,25024
50
90
9T
8
10
121.25
1.25
1.2534
70
125340
710
1,30025
51
9437
78
140380
790
1,45027
57
105
10T
8
10
121.25
1.25
1.2538
78
140390
800
1,45028
58
10542
88
155430
890
1,60031
64
11 6
11 T
8
10
121.25
1.25
1.2542
87
155430
890
1,60031
64
11 647
97
175480
990
1,80035
72
130

SS0ZU–01
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut
Cold Forging Nut Cutting Processed NutClass
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N Old Standard Hexagon Nut
No Mark (w/ Washer)No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
– SERVICE SPECIFICATIONSSTANDARD BOLT
SS–3
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

SS0G6–02
SS–4
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
MANUAL TRANSAXLE (E251)
SERVICE DATA
Input shaft
3rd & 4th gear journal diameter Min.
5th gear journal diameter Min.
Runout Max.
35.950 mm (1.4154 in.)
27.950 mm (1.1004 in.)
0.05 mm (0.0020 in.)
Output shaft
1st gear journal diameter Min.
2nd gear journal diameter Min.
Runout Max.
37.526 mm (1.4774 in.)
34.512 mm (1.3588 in.)
0.06 mm (0.0024 in.)
Oil pump clearance
Rotor body STD
Max.
Rotor tip STD
Max.
Rotor side STD
Max.
0.10 – 0.16 mm (0.0039 – 0.0063 in.)
0.30 mm (0.0118 in.)
0.08 – 0.15 mm (0.0031 – 0.0059 in.)
0.30 mm (0.0118 in.)
0.03 – 0.08 mm (0.0012 – 0.0031 in.)
0.15 mm (0.0059 in.)
Gear thrust clearance
1st & 3rd STD
Max.
2nd STD
Max.
4th STD
Max.
5th STD
Max.
0.10 – 0.35 mm (0.0039 – 0.0138 in.)
0.40 mm (0.0157 in.)
0.10 – 0.45 mm (0.0039 – 0.0177 in.)
0.50 mm (0.0197 in.)
0.10 – 0.55 mm (0.0039 – 0.0217 in.)
0.60 mm (0.0236 in.)
0.10 – 0.57 mm (0.0039 – 0.0224 in.)
0.65 mm (0.0256 in.)
Gear radial clearance
1st & 4th STD
2nd & 3rd STD
5th STD
1st, 2nd, 3rd, 4th & 5th Max.
0.009 – 0.051 mm (0.0004 – 0.0020 in.)
0.009 – 0.053 mm (0.0004 – 0.0021 in.)
0.009 – 0.050 mm (0.0004 – 0.0020 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance
1st, 4th & 5th Min.
2nd & 3rd Min.
0.8 mm (0.031 in.)
0.7 mm (0.028 in.)
Drive in depth
Control shaft cover oil seal
Select inner lever slotted spring pin
No.1 shift inner lever slotted spring pin
No.2 shift inner lever slotted spring pin
0 – 1.0 mm (0 – 0.039 in.)
0
0.5 mm (0
0.020 in.)
0
0.5 mm (0
0.020 in.)
0
0.5 mm (0
0.020 in.)
Input shaft snap ring thickness Mark
No.2 clutch hub H
J
K
L
M
N
P
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)

– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
SS–5
Input shaft snap ring thickness Mark
No.3 clutch hub a
b
c
d
e
f
g
h
j
Ball bearing 1
2
3
4
5
6
7
8
1.75 mm (0.0689 in.)
1.80 mm (0.0709 in.)
1.85 mm (0.0729 in.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0847 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
Differential pinion to side gear backlash STD0.05 – 0.20 mm (0.0020 – 0.0079 in.)
Differential side gear thrust washer thickness
0.80 mm (0.0315 in.)
0.90 mm (0.0354 in.)
1.00 mm (0.0394 in.)
1.10 mm (0.0433 in.)
1.20 mm (0.0472 in.)
1.30 mm (0.0512 in.)
1.40 mm (0.0551 in.)
Differential case side bearing preload (at starting)
New bearing (Output shaft preload plus)
Reused bearing (Output shaft preload plus)
0.2 – 0.3 N·m (1.8 – 3.5 kgf·cm, 1.6 – 3.0 in.·lbf)
0.1 – 0.2 N·m (1.1 – 2.2 kgf·cm, 1.0 – 1.9 in.·lbf)
Differential side bearing adjusting shim thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)

SS–6
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
Output shaft bearing preload (at starting)
New bearing
Reused bearing
0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)
0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)
Output shaft rear bearing adjusting shim thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
1.30 mm (0.0512 in.)
1.35 mm (0.0531 in.)
1.40 mm (0.0551 in.)
1.45 mm (0.0571 in.)
1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
1.80 mm (0.0709 in.)
1.85 mm (0.0728 in.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)

SS0G7–04
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
SS–7
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transaxle upper side x Engine Bolt A
Bolt B64
29650
29647
21
Transaxle lower side x Engine Bolt A
Bolt B
Bolt C
Bolt D
Bolt E40
40
8
20
46408
408
82
204
47030
30
71 in.·lbf
15
34
Diesel throttle body x Engine unit2121415
No.1 air tube assembly x Engine unit2525518
Diesel throttle body with No.2 air tube assembly x Engine unit2525518
Engine front mounting x Engine front mounting bracket8789064
Engine front mounting x Transaxle6465047
Engine rear mounting x Engine rear mounting bracket981,00072
Engine rear mounting x Transaxle6465047
Starter x Starter wire1515311
Starter x Transaxle3940029
Transaxle case protector x Transaxle2525018
Clutch release cylinder x Clutch housing121209
Clutch line bracket x Transaxle Bolt A
(See page MX–4) Bolt B12
4.9120
509
43 in.·lbf
Engine left mounting x Bracket8789064
Engine left mounting Bracket x Transaxle5253038
Front wheel1031,05076
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe4849035
Engine rear mounting x Center member7374054
Engine rear mounting bracket x Body6465047
Engine rear mounting bracket x Engine rear mounting8789064
Engine front mounting x Center member5254038
Engine front mounting bracket x Transaxle6465047
Engine front mounting bracket x Engine front mounting8789064
Front transport hook x Center member3940029
Engine mounting center member x Body7374054
Transaxle case protector x Transaxle2525018
No.2 selecting bellcrank with selecting bellcrank support2020014
Shift and select lever shaft lock bolt4950036
Shift and select lever shaft assembly x Transmission case2020014
Transmission case cover x Transmission case2930022
Breather plug4950036
Output shaft lock nut1231,25090
Shift fork and shift head set bolt2424017
Rear bearing retainer x Transmission case4243031
Straight screw plug2525018
Straight screw plug (Reverse restrict pin)131309
Reverse idler gear shaft lock bolt2930022

SS–8
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
Transmission case x Transaxle case
2930022
Transmission oil pipe x Transaxle case1717513
Reverse shift arm bracket assembly x Transaxle case1717513
Transmission oil pump assembly x Transaxle case1717513
Transaxle case receiver x Transaxle case7.47565 in.·lbf
Clutch release fork support4748035
Control lever housing support bracket x Transaxle case1717513
Vehicle speed sensor1717513
Clutch release line bracket x Transaxle case1717513
Back–up light switch4041030
Filler and drain plugs4950036
No.1 and No.2 oil receiver pipes x Transmission case1717513
Transmission oil cooler sub–assembly x Elbow3435025
Elbow x Transaxle case2727520
Transmission oil pump case x Oil pump cover101058
Differential left case x Differential right case6364046
Ring gear set bolt1241,26091
Shift lever assembly x Body121209
Retainer x Body4.95043 in.·lbf
Grommet retainer x Body4.95043 in.·lbf