TOYOTA AVENSIS 1999 Supplement

1999 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Jun. 15, 1999 01–990615–00
FOREWORD
This supplement has been prepared to provide information covering general se\
rvice repairs for the chassis
and body of the TOYOTA AVENSIS/CORONA which underwent changes in August, 1999.Applicable models: AT220, 221 series
ST220 series
CT220 series
CDT220 series
Pub. No.Manual NamePub. No.

A VENSIS/CORONA Chassis and Body Repair
ManualRM599E
2C Engine Repair Manual SupplementRM297E

4A–FE Engine Repair ManualRM296E
2C–T Engine Repair Manual SupplementRM494E

7A–FE Engine Repair ManualRM325E
2C–T, 2C–TE Engine Repair Manual SupplementRM612E

4A–FE Engine Repair Manual SupplementRM397E
1CD–FTV Engine Repair ManualRM697E

7A–FE Engine Repair Manual SupplementRM435E
A241L, A241E Automatic Transaxle Repair ManualRM177E

4A–FE, 7A–FE Engine Repair Manual SupplementRM611E
A245E Automatic Transaxle Repair ManualRM350E

3S–FE Engine Repair ManualRM395E
AVENSIS/CORONA Electrical Wiring DiagramEWD330Y

3S–FE Engine Repair Manual SupplementRM495E
AVENSIS/CORONA Electrical Wiring Diagram
SupplementEWD373F

3S–FE Engine Repair Manual SupplementRM609E
AVENSIS/CORONA New Car FeaturesNCF145E

1C, 2C, 2C–T Engine Repair ManualRM025E
AVENSIS/CORONA New Car Features SupplementNCF168E
All information in this manual is based on the latest product information at the time of\
publication. However,
specifications and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
AZT 220 series
Manual Name
ZZT220, 221 series
For the service specifications and repair procedures of the above model othe\
r than those listed in this supple-
ment, refer to the following manuals.

CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non–specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.

Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of ”IN” section.

The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non–specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.

If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.

It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.

INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
E251 MANUAL TRANSAXLE
SUSPENSION AND AXLE
BRAKE
STEERING
SUPPLEMENTAL RESTRAINT SYSTEM
BODY ELECTRICAL
BODY
AIR CONDITIONING
ALPHABETICAL INDEX

INTRODUCTION
HOW TO USE THIS MANUAL IN–1. . . . . . . . . . . . .
GENERAL INFORMATION IN–1. . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION IN–3. . . . . . . . . .
VEHICLE IDENTIFICATION AND ENGINE SERIAL
NUMBER IN–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS IN–4. . . . . . . . . . . . . . . . .
GENERAL INFORMATION IN–4. . . . . . . . . . . . . . . . . .
VEHICLE LIFT AND SUPPORT LOCATIONS IN–7. .
FOR ALL OF VEHICLES IN–9. . . . . . . . . . . . . . . . . .
PRECAUTION IN–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS IN–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION IN–18. . . . . . . . . . . . . . . . . .
HOW TO PROCEED
WITH TROUBLESHOOTING IN–19. . . . . . . . . . . . . .
HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE IN–29. . . . . . . . . . . . . . .
TERMS IN–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS USED IN THIS MANUAL IN–34. . . .

IN00U–34
N17080
Filler Cap
Float
Reservoir Tank

Grommet
Clip
Slotted Spring Pin
: Specified torque

Non–reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot

Gasket
Lock Nut
Clevis Pin
Clevis
N·m (kgf·cm, ft·lbf)
12 (120, 9)
15 (155, 11)
– INTRODUCTIONHOW TO USE THIS MANUAL
IN–1
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN–19.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

Illustration:
what to do and where
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350–30020 (09350–06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40
1.70 mm (0.0551
 
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392
 
kgf/cm
2 or 57
114 psi) as shown
in the illustration. IN–2
– INTRODUCTIONHOW TO USE THIS MANUAL
The procedures are presented in a step–by–step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example

This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

IN06B–05
B02393
B A
B02403
4A–FE and 7A–FE engines 3S–FE engine 2C–T, 2C–TE and 1CD–FTV engines
– INTRODUCTIONIDENTIFICATION INFORMATION
IN–3
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped in the engine
compartment. This number has also been stamped on the
manufacturer ’s label.
A: Vehicle Identification Number
B: Manufacturer’s Label
2. ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.

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.

BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation Part Name Symbol Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKERFUSE
M–FUSE
H–FUSE
FL
CB
– INTRODUCTIONREPAIR INSTRUCTIONS
IN–5
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN–7).
(1) If the vehicle is to be jacked up only at the front or
rear end, make sure to place the stopper under the
wheels at the opposite end to block them in order to
ensure safety.