engine 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)

SA109–02
F08959
1CD–FTV Engine
Tie Rod End
ABS Speed Sensor
Cotter Pin
Lock Cap

Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torqueLH Drive Shaft
Snap Ring

Cotter Pin
Center Bearing Bracket
64 (650, 47)
49 (500, 36)
8.0 (82, 71 in.·lbf)
216 (2,200, 159)
RH Drive Shaft
127 (1,300, 94)
Lower Suspension Arm
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–1
FRONT DRIVE SHAFT
COMPONENTS

F08949
Non–reusable part
Dynamic Damper

Dust Cover
Snap Ring Outboard Joint Shaft

Boot

Boot
Tripod
RH Inboard Joint Shaft
Snap Ring
Bearing CaseStraight Pin
Inboard Joint Shaft

Dust Cover LH
Boot ClampBearing

Snap Ring 1CD–FTV Engine

Dynamic Damper Clamp

Boot Clamp

Boot Clamp

Boot Clamp SA–2
– SUSPENSION AND AXLEFRONT DRIVE SHAFT

BR11S–01
F08980
F08981
F08982
New O–Ring
F08970
F08969
– BRAKEVACUUM PUMP (1CD–FTV)
BR–7
REASSEMBLY
1. INSTALL COUPLING
(a) Place the coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
2. INSTALL ROTOR INTO CASING
Coat the rotor with engine oil, and install it to the rotor shaft.
3. INSTALL 5 BLADES
(a) Coat the 5 blades with engine oil.
(b) Install the 5 blades with the round end facing outward.
HINT:
Be sure that the blades and rotor surfaces are even.
4. INSTALL END COVER
(a) Coat 2 new O–rings with engine oil, and place them to the
casing.
(b) Place the vacuum pump on the vise, as shown in the il-
lustration.
NOTICE:
Do not tighten the vise.
(c) Place the end cover, and temporarily install the 3 bolts.
(d) Using a pin punch and hammer, drive in the 2 straight
pins.
(e) Using soft jaws on the vise, place the vacuum pump in the
vise.
NOTICE:
Do not tighten the vise too tightly.
(f) Tighten the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

BR11T–01


F08964
New O–RingVacuum Hose
Oil Hose
– BRAKEVACUUM PUMP (1CD–FTV)
BR–9
INSTALLATION
1. INSTALL VACUUM PUMP
(a) Coat 2 new O–rings with engine oil, and install them to the
vacuum pump.
(b) Insert the vacuum pump, align the coupling with slit of the
camshaft.
(c) Install the 2 bolts.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
2. CONNECT 2 VACUUM HOSES AND OIL HOSE

P06717
SR0I6–02
F01334
98 N (10kgf, 22 lbf) 4A–FE and 7A–FE Engines
Vane Pump
Pulley
Crank PulleyA/C
Compressor
Pulley
F03726
98 N (10kgf, 22 lbf) 3S–FE Engine
Vane Pump
Pulley
Crank Pulley
F01335
2C–T, 2C–TE and 1CD–FTV Engines
Vane Pump Pulley
A/C Compressor
Pulley Crank Pulley 98 N (10 kgf, 22 lbf)
– STEERINGDRIVE BELT
SR–1
DRIVE BELT
INSPECTION
1. INSPECT DRIVE BELT
Visually check the belt for excessive wear, frayed cords, etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
missing chunks from the ribs are found on the belt, it should be
replaced.
2. CHECK DRIVE BELT TENSION
Measure the drive belt deflection.
Drive belt tension: at 98 N (10 kgf, 22 lbf)
4A–FE and 7A–FE engines:
New belt5 – 6 mm (0.20 – 0.24 in.)
Used belt6 – 8 mm (0.24 – 0.31 in.)
3S–FE engine:
New belt8 – 10 mm (0.31 – 0.39 in.)
Used belt10 – 13 mm (0.39 – 0.51 in.)
2C–T, 2C–TE and 1CD–FTV engines:
New belt11 – 14 mm (0.43 – 0.55 in.)
Used belt15 – 18 mm (0.59 – 0.71 in.)

P06723
CORRECT WRONGWRONG
Z11352
SR–2
– STEERINGDRIVE BELT
HINT:

”New belt” refers to a belt which has been used less than
5 minutes on a running engine.

”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooves.

Check with your hand to confirm that the belt has not
slipped out of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
(Reference)

Using a belt tension gauge, measure the drive belt ten-
sion.
Drive belt tension:
4A–FE, 7A–FE and 3S–FE engines:
New belt441 – 539 N (45 – 55 kgf)
Used belt245 – 392 N (25 – 40 kgf)
2C–T, 2C–TE and 1CD–FTV engines:
New belt539 – 637 N (55 – 65 kgf)
Used belt245 – 392 N (25 – 40 kgf)
If the belt tension is not as specified, adjust it.