1999 TOYOTA AVENSIS manual transmission

IN044–07
IN–34
– INTRODUCTIONTERMS
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti–Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
BACSBoost Altitude Compensation System
BATBattery
B/LBi–Level
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CDCompact Disc
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CRSChild Restraint System
CTRCenter
DCDirect Current
DIFF.Differential
DIFF. LOCKDifferential Lock
DLCData Link Connector
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
ECTElectronic Control Transmission
ECUElectronic Control Unit
EDUElectronic Driving Unit
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
ELREmergency Locking Retractor
E–VRVElectronic Vacuum Regulating Valve

– INTRODUCTIONTERMS
IN–35
FFFront–Engine Front–Wheel–Drive
FIPGFormed In Place Gasket
FLFusible Link
FrFront
FRFront–Engine Rear–Wheel–Drive
FWDFront–Wheel–Drive
GNDGround
H/BHatchback
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HTHard Top
HWSHeated Windshield System
IACIdle Air Control
IFSIndependent Front Suspension
IGIgnition
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft–Hand
LHDLeft–Hand Drive
LOLow
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPIMultipoint Electronic Fuel Injection
MPXMultiplex Communication System
M/TManual Transmission
NNeutral
No.Number
O2SOxygen Sensor
O/DOverdrive
OPTOption
P & BVProportioning And Bypass Valve
PCSPower Control System

PP27T–01
– PREPARATIONMANUAL TRANSAXLE (E251)
PP–1
MANUAL TRANSAXLE (E251)
SST (Special Service Tools)
09223–15020Oil Seal & Bearing ReplacerDifferential case oil seal
09308–00010Oil Seal PullerOutput shaft front bearing outer
race
09316–20011Transfer Bearing ReplacerDifferential case tapered roller
bearing
09316–60011Transmission & Transfer Bearing
Replacer
(09316–00011)Replacer Pipe
(09316–00021)Replacer ”A”
(09316–00041)Replacer ”C”1st gear
No.1 hub sleeve
Differential case tapered roller
bearing outer race
(09316–00071)Replacer ”F”Output shaft front bearing
09506–30012Differential Drive Pinion Rear
Bearing Cone ReplacerOutput shaft rear bearing
09506–35010Differential Drive Pinion Rear
Bearing ReplacerNo.2 hub sleeve
3rd gear
Input shaft rear bearing
1st gear bearing inner race
09608–00081Differential Side Bearing Cone
ReplacerInput shaft oil seal
09612–65014Steering Worm Bearing PullerInput shaft bearing
Differential case tapered roller
bearing outer race

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

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)

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

D06621

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

Non–reusable part
 Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse
Restrict Pin  Straight Screw PlugBack–Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Shift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted
Spring PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x 10 x 17


24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)29 (300, 22)
Breather Plug
Gasket

Gasket
Gasket
Gasket
Gasket
Snap Ring
MX–10
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY