TOYOTA AVENSIS 1999 Supplement

MX097–02
D06626
(a)(b)
D06627
D06628
MX–4
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
3. REMOVE LH AND RH ENGINE UNDER COVERS
4. REMOVE NO.1 AIR TUBE ASSEMBLY
(a) Disconnect the No.2 vacuum hose from the E–VRV for
EGR.
(b) Disconnect the No.2 vacuum hose from the VSV for EGR.
(c) Disconnect the VSV connector for EGR.
(d) Disconnect the turbo pressure sensor connector and vac-
uum hose.
(e) Remove the 2 bolts as shown in the illustration.
Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)
(f) Disconnect the 2 hose clips, and remove the No.1 air tube
assembly.
5. REMOVE DIESEL THROTTLE BODY WITH NO.2 AIR
TUBE ASSEMBLY
(a) Disconnect the intake air temperature sensor connector.
(b) Disconnect the throttle control motor connector.
(c) Disconnect the full opener switch connector.
(d) Remove the 3 bolts from the diesel throttle body.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
(e) Remove the 2 bolts as shown in the illustration.
Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)
(f) Disconnect the 2 hose clips, and remove the diesel
throttle body assembly with the No.2 air tube assembly.

D06629
D06639
A
B
D06633
D06636
B AA
D06634
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MX–5
6. REMOVE STARTER
(a) Remove the 2 bolts and disconnect the radiator reservoir
from the radiator.
(b) Disconnect the starter connector.
(c) Remove the nut, and disconnect the starter wire.
Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)
(d) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
7. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts and disconnect the release cylinder
and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
8. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
9. DISCONNECT VEHICLE SPEED SENSOR AND
BACK–UP LIGHT SWITCH CONNECTORS
10. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
11. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 29 N·m (296 kgf·cm, 21 ft·lbf)
12. INSTALL ENGINE SUPPORT FIXTURE
Install the engine hanger in the correct direction.
Parts No.:
Engine hanger: 12281–27010
Bolt: 96122–61020
Torque: 37 N·m (377 kgf·cm, 27 ft·lbf)

D06632AB
D06638
Q10165
Filler Plug
Oil Level
0 – 5 mm
Drain Plug
D06631
MX–6
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
13. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET
BOLTS AND NUT
Torque:
Bolt A: 52 N·m (530 kgf·cm, 38 ft·lbf)
Nut B: 87 N·m (890 kgf·cm, 64 ft·lbf)
14. REMOVE ENGINE LEFT MOUNTING BRACKET
Lower the transaxle side and remove the bolt and bracket.
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
15. REMOVE FRONT WHEEL
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
16. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
17. DRAIN TRANSAXLE OIL
Oil grade: API GL–4 or GL–5
Viscosity: SAE 75W–90
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
18. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, 2 nuts and gasket from the exhaust
manifold.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Remove the 2 bolts, 2 springs, gasket and pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
19. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA–1)
20. REMOVE ENGINE MOUNTING CENTER MEMBER
(a) Remove the 2 bolts and front transport hook.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Support the suspension crossmember with a jack.
(c) Remove the nuts, and disconnect the suction pipe.

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)

MX05P–02
MX–8
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
INSTALLATION
Installation is in the reverse order of removal.
(See page MX–4)
HINT:
After installation, check and inspect items as follows.
Front wheel alignment (See Pub. No. RM599E, page SA–4).
Do the road test.

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

D06653
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
 Precoated partOutput Shaft AssemblyInput Shaft Assembly

Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring
Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x 7Shim
 Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring 
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–11

MX099–01
Q05816
FIPG
Q00449
MX–12
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK–UP LIGHT SWITCH WITH GASKET
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
3. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
4. REMOVE NO.2 SELECTING BELLCRANK WITH SE-
LECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bellcrank with the se-
lecting bellcrank support.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
5. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
6. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY WITH GASKET
Remove the 4 bolts, the shift, select lever shaft assembly and
gasket.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
7. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG:
Part No. 08826–00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
8. REMOVE BREATHER PLUG WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
9. REMOVE OUTPUT SHAFT LOCK NUT
(a) Remove the lock nut.
(b) Engage the gear double meshing.
(c) Remove the lock nut.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
(d) Disengage the gear double meshing.
10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(b) Remove the No.3 hub sleeve and No.3 shift fork.

Q05849
SST
Z01304
Z01306
Q00299
Z01308
SST
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–13
11. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950–30011
12. MEASURE 5TH GEAR THRUST CLEARANCE AND
RADIAL CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 – 0.57 mm (0.0039 – 0.0224 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
(b) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009 – 0.050 mm (0.0004 – 0.0020 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
13. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of the reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
a1.75 (0.0689)f2.00 (0.0787)
b1.80 (0.0709)g2.05 (0.0807)
c1.85 (0.0729)h2.10 (0.0827)
d1.90 (0.0748)j2.15 (0.0847)
e1.95 (0.0768)––
(b) Using SST, remove the No.3 clutch hub with the synchro-
nizer ring and 5th gear.
SST 09950–30011
14. REMOVE NEEDLE ROLLER BEARING AND SPACER
15. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and
rear bearing retainer.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent