1999 TOYOTA AVENSIS oil

FI1066
IN03Z–01
IN–4
– INTRODUCTIONREPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Installation and removal of battery terminal:
(1) Before performing electrical work, disconnect the
negative (–) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (–)
terminal.
(3) When disconnecting the terminal cable, to prevent
damage to the battery terminal, loosen the cable
nut and raise the cable straight up without twisting
or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non–reusable parts
(1) Always replace cotter pins, gaskets, O–rings and oil
seals, etc. with new ones.
(2) Non–reusable parts are indicated in the component
illustrations by the ”
” symbol.
(f) Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
(3) Precoated parts are indicated in the component il-
lustrations by the ”” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.

– INTRODUCTIONFOR ALL OF VEHICLES
IN–15
(h) SEAT BELT PRETENSIONER
(1) Never measure the resistance of the seat belt pre-
tensioner. (This may cause the pretensioner oper-
ates, which is very dangerous.)
(2) Oil or water should not be put on the front seat outer
belt and the front seat outer belt should not be
cleaned with detergents of any kind.
(3) Store the front seat outer belt where the ambient
temperature remains below 80
C (176
F), without
high humidity and away from electrical noise.
(4) When using electric welding, first disconnect the
connector (yellow color and 2 pins) installed at the
center pillar lower garnish before starting work.
(5) When disposing of a vehicle or a front seat outer
belt alone, the seat belt pretensioner should be acti-
vated before disposal (See Pub. No. RM599E,
page BO–153). Perform the operation in a safe
place away from electrical noise.
(i) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved
in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sen-
sor mounted on the floor. If the connectors are con-
nected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause
undesired ignition of the supplemental restraint sys-
tem.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (–) terminal cable is discon-
nected from the battery, even if only loosing the set
bolts of the airbag sensor assembly.
(j) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness and the cowl wire harness assembly
and floor wire harness assembly. The wires for the SRS
wire harness are encased in a yellow corrugated tube. All
the connectors for the system are also a standard yellow
color. If the SRS wire harness becomes disconnected or
the connector becomes broken due to an accident, etc.,
repair or replace it as shown on Pub. No. RM599E, page
RS–65.

IN–16
– INTRODUCTIONFOR ALL OF VEHICLES
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off and prolonged braking.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two–way radios and cellular telephones, observe
the following precautions.
(a) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic sys-
tem.
(b) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s
electronic systems. For details about ECU and sensors locations, refer to the section on the applicable
component.
(c) Do not wind the antenna feeder together with the other wiring as much as possible, also avoid running
the antenna feeder parallel with other wire harnesses.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install powerful mobile communications system.
4. FOR USING HAND–HELD TESTER
CAUTION:
Observe the following items for safety reasons:
Before using the hand–held tester, the hand–held tester’s operator manual should be read thor-
oughly.
Be sure to route all cables securely when driving with the hand–held tester connected to the
vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Two persons are required when test driving with the hand–held tester, one person to drive the
vehicle and the other person to operate the hand–held tester.

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

PP0VF–02
– PREPARATIONMANUAL TRANSAXLE (E251)
PP–5
LUBRICANT
ItemCapacityClassification
Manual transaxle oil (w/ Differential oil)3.9 liters (4.1 US qts, 3.4 Imp. qts)API GL–4 or GL–5
SAE 75W–90

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.)

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

SS0IF–02
– SERVICE SPECIFICATIONSSTEERING
SS–13
STEERING
SERVICE DATA
DRIVE BELT
4A–FE and 7A–FE engines:
Drive belt deflection New belt5 – 6 mm (0.20 – 0.24 in.)
Drive belt deflection Used belt6 – 8 mm (0.24 – 0.31 in.)
*Drive belt tension New belt441 – 539 N (45 –55 kgf)
*Drive belt tension Used belt245 – 392 N (25 – 40 kgf)
3S–FE engine:
Drive belt deflection New belt8 – 10 mm (0.31 – 0.39 in.)
Drive belt deflection Used belt10 – 13 mm (0.39 – 0.51 in.)
* Drive belt tension New belt441 – 539 N (45 – 55 kgf)
* Drive belt tension Used belt245 – 392 N (25 – 40 kgf)
2C–T, 2C–TE and 1CD–FTV engines:
Drive belt deflection New belt11 – 14 mm (0.43 – 0.55 in.)
Drive belt deflection Used belt15 – 18 mm (0.59 – 0.71 in.)
* Drive belt tension New belt539 – 637 N (55 – 65 kgf)
* Drive belt tension Used belt245 – 392 N (25 – 40 kgf)
POWER STEERING FLUID
Oil level rise Maximum5 mm (0.20 in.)
4A–FE and 7A–FE engines:
Oil pressure at idle speed with valve closed Minimum8,238 kPa (84 kgf/cm2, 1,195 psi)
3S–FE engine:
Oil pressure at idle speed with valve closed Minimum9,022 kPa (92 kgf/cm2, 1,309 psi)
2C–T, 2C–TE and 1CD–FTV engines:
Oil pressure at idle speed with valve closed Minimum8,826 kPa (90 kgf/cm2, 1,280 psi)
PS VANE PUMP (2C–T, 2C–TE and 1CD–FTV engines)
Pump rotating torque Maximum0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf)
Pump shaft and front housing bushing oil clearance STD
Maximum0.01 – 0.03 mm (0.0004 – 0.0012 in.)
0.07 mm (0.0028 in.)
Vane plate height Minimum8.1 mm (0.319 in.)
Vane plate thickness Minimum1.797 mm (0.0708 in.)
Vane plate length Minimum14.988 mm (0.5901 in.)
Vane plate and pump rotor groove clearance Maximum0.03 mm (0.0012 in.)
Vane plate length Pump rotor and cam ring mark
None14.996 – 14.998 mm (0.59039 – 0.59047 in.)
114.994 – 14.996 mm (0.59032 – 0.59039 in.)
214.992 – 14.994 mm (0.59024 – 0.59032 in.)
314.990 – 14.992 mm (0.59016 – 0.59024 in.)
414.988 – 14.990 mm (0.59008 – 0.59016 in.)
Flow control valve spring length Minimum36.0 mm (1.417 in.)
*: For use with belt tension gauge