check oil TOYOTA AVENSIS 1999 Supplement

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.

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.

MX01Z–04
– MANUAL TRANSAXLE (E251)TROUBLESHOOTING
MX–1
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX–4
MX–4
MX–9
MX–9
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O–Ring (Worn or damaged)MX–4
MX–9
MX–9
MX–9
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX–48
MX–9
MX–23
MX–30
MX–9
MX–23
MX–30
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX–9
MX–9
MX–9
MX–9

MX05W–02
MT0782
WM0066
Z00192
SST
Z00194
SST
Q08014
SST MX–18
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
middle No.5 synchronizer ring in one direction while push-
ing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If it does not lock, replace the synchronizer ring.
2. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT BEARING
AND OIL SEAL
(a) Remove the 3 bolts and transaxle case receiver.
(b) Using SST, pull out the bearing.
SST 09612–65014
(c) Using a screwdriver, remove the oil seal.
(d) Using SST, drive in a new oil seal.
SST 09608–00081, 09950–70010 (09951–07150)
(e) Coat the lip of seal with MP grease.
(f) Using SST, drive in a new bearing.
SST 09950–60010 (09951–00580), 09950–70010
(09951–07150)
(g) Install the transaxle case receiver.
(h) Install and torque the 3 bolts.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)

MX02H–02
Z00242
Z00243
Z00244
– MANUAL TRANSAXLE (E251)OIL PUMP
MX–39
INSPECTION
1. CHECK ROTOR BODY CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and oil pump case.
Standard clearance:
0.10 – 0.16 mm (0.0039 – 0.0063 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
2. CHECK ROTOR TIP CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the tip clearance between
the drive and driven rotors.
Standard clearance:
0.08 – 0.15 mm (0.0031 – 0.0059 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
3. CHECK SIDE CLEARANCE
Using a precision straight edge and feeler gauge, measure the
side clearance of both rotors.
Standard clearance:
0.03 – 0.08 mm (0.0012 – 0.0031 in.)
Maximum clearance:
0.15 mm (0.0059 in.)

Z00295
MX09B–01
Z00296
Z00297
D06655
Matchmarks
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–45
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washer to the side gear.
(b) Install the 4 pinions and thrust washers to the spider.
(c) Install the side gear and spider with the 4 pinions to the
differential left case.
(d) Using a dial indicator, measure the backlash of the pinion
gear while holding the differential left case.
Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079
in.)
HINT:
Push the pinion gear and spider with the 4 pinions to the differ-
ential left case.
(e) Install the side gear and spider with the 4 pinions to the
right side of the differential case. Check the side gear
backlash.
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)–
(g) Align the matchmarks on the differential cases.
(h) Using a plastic hammer, carefully tap the differential case
to install it.
(i) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.

SA02Z–03
SA–10
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
INSTALLATION
1. LH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Install a new snap ring to the inboard joint shaft.
(b) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(c) Set the snap ring with opening side facing downward.
(d) Using a brass bar and hammer, install the drive shaft.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
HINT:
Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feel-
ing when driving it in.
(e) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction.
(f) Check that the drive shaft cannot be removed by hand.
2. RH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(b) Install the drive shaft with the center bearing bracket.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
(c) Install the 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
3. CONNECT DRIVE SHAFT TO AXLE HUB
NOTICE:
Be careful not to damage the boot and ABS speed sensor rotor.
4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
5. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle.
(b) Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
6. INSTALL DRIVE SHAFT LOCK NUT
(a) While applying brakes, install the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
(b) Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
7. w/ABS:
INSTALL ABS SPEED SENSOR AND BOLT
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
8. FILL AND CHECK GEAR OIL (See page MX–4)
9. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
10. CHECK FRONT WHEEL ALIGNMENT (See Pub. No. RM599E on page SA–4)
11. CHECK ABS SPEED SENSOR SIGNAL (See Pub. No. RM599E on page DI–115)

BR11O–01
F08965Non–reusable part N·m (kgf·cm, ft·lbf) : Specified torque
Vacuum Pump

Gasket Vacuum Hose
Casing
Rotor
BladeStraight
Pin
End Cover Check Valve
Union
O–Ring
Vacuum Hose

O–Ring

Gasket

Gasket

O–Ring
Oil Hose
Straight Pin
21 (214, 15)
74 (750, 54)
14 (140, 10)
7.8 (80, 68 in.·lbf)

Snap Ring
Coupling
BR–2
– BRAKEVACUUM PUMP (1CD–FTV)
VACUUM PUMP (1CD–FTV)
COMPONENTS

F03737
4A–FE and 7A–FE Engines
2C–T, 2C–TE, 3S–FE and 1CD–FTV
EnginesSR0I8–02
R07281
Normal
Abnormal
R10552Engine IdlingEngine Stopped 5 mm (0.20 in.) or less
– STEERINGPOWER STEERING FLUID
SR–3
POWER STEERING FLUID
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir / reservoir cap dipstick.
If the fluid is cold, check that it is within the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80
C (176
F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem (See Pub. No. RM599E on page SR–5).
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system (See Pub.
No. RM599E on page SR–5).
(i) Check the fluid level.

SR0WD–01
F03717
F03718
F03719
Vinyl Tape
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–9
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Temporarily install the vane pump pulley set nut.
(c) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE SUCTION PORT UNION
(a) Remove the bolt and suction port union.
(b) Remove the O–ring from the union.
3. REMOVE PRESSURE PORT UNION
(a) Remove the pressure port union.
(b) Remove the O–ring from the union.
4. REMOVE FLOW CONTROL VALVE AND SPRING
5. REMOVE REAR HOUSING, WAVE WASHER AND SIDE
REAR PLATE
(a) Using 2 screwdrivers, remove the snap ring.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the vane pump shaft.
(c) Using a plastic hammer, tap out the rear housing, wave
washer and side rear plate.
(d) Remove the O–ring from the rear housing.
(e) Remove the O–ring from the side rear plate.
6. REMOVE CAM RING AND 10 VANE PLATES
NOTICE:
Be careful not to drop the plate.
7. REMOVE VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
8. REMOVE VANE PUMP ROTOR AND SIDE FRONT
PLATE
(a) Using a screwdriver, remove the snap ring from the vane
pump shaft.
(b) Remove the vane pump rotor and side front plate.
(c) Remove the 2 O–rings from the side front plate.
9. REMOVE SHORTER STRAIGHT PIN
Using pliers, remove the shorter straight pin from the side front
plate.