light TOYOTA AVENSIS 1999 Supplement

DI694–01
DI–4
– DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table
below (Proceed to the page given for that circuit.).
DTC No.
(See Page)Detection ItemTrouble AreaSRS
Warning Light
81
(DI–8)Short in curtain shield airbag (RH) cir-
cuit (to ground)
Curtain shield airbag (RH) (squib)

Airbag sensor assembly

Wire harness
Blink
82
(DI–12)Short in curtain shield airbag (RH) cir-
cuit circuit (to B+)
Curtain shield airbag (RH) (squib)

Airbag sensor assembly

Wire harness
Blink
83
(DI–15)Short in curtain shield airbag (RH) squib
circuit
Curtain shield airbag (RH) (squib)

Airbag sensor assembly

Wire harness
Blink
84
(DI–18)Open in curtain shield airbag (RH) squib
circuit
Curtain shield airbag (RH) (squib)

Airbag sensor assembly

Wire harness
Blink
85
(DI–21)Short in curtain shield airbag (LH) circuit
(to ground)
Curtain shield airbag (LH) (squib)

Airbag sensor assembly

Wire harness
Blink
86
(DI–25)Short in curtain shield airbag (LH) circuit
circuit (to B+)
Curtain shield airbag (LH) (squib)

Airbag sensor assembly

Wire harness
Blink
87
(DI–28)Short in curtain shield airbag (LH) squib
circuit
Curtain shield airbag (LH) (squib)

Airbag sensor assembly

Wire harness
Blink
88
(DI–31)Open in curtain shield airbag (LH) squib
circuit
Curtain shield airbag (LH) (squib)

Airbag sensor assembly

Wire harness
Blink
HINT:

When the SRS warning light remains lit up and the DTC is the normal code, this means a voltage source
drops.
This malfunction is not stored in memory by the airbag sensor assembly and if the power source volt-
age returns to normal, the SRS warning light will automatically go out.

When 2 or more codes are indicated, the codes will be displayed in numeral order starting from the
lowest numbered code.

If a code not listed on the chart is displayed, the airbag sensor assembly is faulty.

DI695–01
H11591
Combination Meter
(Warning Light)Steering Wheel Pad
(with Airbag)
Airbag Sensor Assembly Front Passenger
Airbag Assembly
Side Airbag Assembly
(LH)
Seat Belt
Pretensioner (LH)Side Airbag Assembly (RH)
Seat Belt
Pretensioner (RH)
Front Airbag
Sensor (LH)
Front Airbag Sensor (RH)
Side and Curtain Shield
Airbag Sensor (RH) Side and Curtain Shield
Airbag Sensor (LH)Curtain Shield Airbag
Assembly (LH)Curtain Shield Airbag Assembly (RH)
– DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DI–5
PARTS LOCATION

DI696–01
H01357
C6C5C4
A B
1 2 3 4 5 6A BA B
7 8 9 10 11 121 2 3 4 5 6
7 8 9 10 11 12 1 2 3 4 5 6
7 8 9 10 11 12
23 24 25 26 27 2813 14 15 16 17
18 19 20 21 22 DI–6
– DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
TERMINALS OF ECU
No.SymbolTerminal Name
A–Electrical Connector Check Mechanism
B–Electrical Connector Check Mechanism
C4 – 1SFL–Squib (Side, LH)
C4 – 2SFL+Squib (Side, LH)
C4 – 5PL+Squib (Seat Belt Pretensioner, LH)
C4 – 6PL–Squib (Seat Belt Pretensioner, LH)
C4 – 7ESLSide Airbag Sensor (LH)
C4 – 9FSLSide Airbag Sensor (LH)
C4 – 10SSL+Side Airbag Sensor (LH)
C4 – 12VUPLSide Airbag Sensor (LH)
C5 – 3LASRS Warning Light
C5 – 5IG2Power Source (IGN Fuse)
C5 – 6ACCPower Source (CIG Fuse)
C5 – 7ICL+Squib (Curtain Shield Airbag, LH)
C5 – 8ICL–Squib (Curtain Shield Airbag, LH)
C5 – 9SR+Front Airbag Sensor (RH)
C5 – 10P+Squib (Passenger)
C5 – 11P–Squib (Passenger)
C5 – 12SILDiagnosis
C5 – 13D–Squib (Driver)
C5 – 14D+Squib (Driver)
C5 – 15SL+Front Airbag Sensor (LH)
C5 – 16ICR–Squib (Curtain Shield Airbag, RH)
C5 – 17ICR+Squib (Curtain Shield Airbag, RH)
C5 – 19TcDiagnosis

D06618
RH Drive Shaft
LH Drive
Shaft
216 (2,200, 159)
Lock Nut Cap

Cotter Pin
Snap Ring
Front Exhaust Pipe
Engine Mounting
Center Member
LH Engine Under Cover RH Engine Under Cover
64 (650, 47)
Transaxle Case
Protector
25 (250, 18)
Back–Up Light
Switch Connector
Speed Sensor
Connector
Front Transport
HookHole Plug
Hole PlugHole Cover
64 (650, 47)
39 (400, 29)
73 (740, 54)
73 (740, 54)
52 (540, 38)
Tie Rod End
Engine Rear
Mounting Bracket
64 (650, 47)
98 (1,000, 72)
29 (300, 22)
64 (650, 47)
49 (500, 36)
127 (1,300, 94)
Ground Cable
Engine Front
Mounting Bracket
Engine Front
Mounting
Suction Pipe
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
Gasket
Gasket
8.0 (82, 71in.·lbf)
40 (408, 30)
x 10Bolt with Spring
20 (204, 15)
46 (470, 34)
62 (630, 46)
48 (490, 35)
40 (408, 30)
87 (890, 64)
64 (650, 47)
x 10
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MX–3

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)

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)

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

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.

MX02A–03
MT0780
MT0786
WM0064
WM0065
MX–26
– MANUAL TRANSAXLE (E251)INPUT SHAFT
INSPECTION
1. INSPECT 3RD GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(c) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
2. INSPECT 4TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.

WM0064
MX02E–03
WM0065
MT0780
MT0787
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
MX–33
INSPECTION
1. INSPECT 1ST GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT 2ND GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(c) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.