service TOYOTA AVENSIS 1999 Supplement

PP27U–01
PP–6
– PREPARATIONSUSPENSION AND AXLE
SUSPENSION AND AXLE
SST (Special Service Tools)
09240–00020Wire Gauge Set
09316–60011Transmission & Transfer Bearing
Replacer
(09316–00041)Replacer ”C”
09520–01010Drive Shaft Remover Attachment
09520–24010Differential Side Gear Shaft
Puller
(09520–32040)Shocker Set
09521–24010Drive Shaft Boot Clamping Tool
09608–16042Front Hub Bearing Adjusting Tool
(09608–02021)Bolt & Nut
(09608–02041)Retainer
09710–30021Suspension Bushing Tool Set
(09710–03121)Bushing Remover Base

PP27X–01
PP–12
– PREPARATIONSTEERING
STEERING
SST (Special Service Tools)
09640–10010Power Steering Pressure Gauge
SetPower steering fluid
(09641–01010)Gauge Assy
(09641–01030)Attachment B
(09641–01060)Attachment E
09950–60010Replacer SetPS vane pump
(2C–T, 2C–TE and 1CD–FTV
engines)
(09951–00310)Replacer 31
09950–70010Handle SetPS vane pump
(2C–T, 2C–TE and 1CD–FTV
engines)
(09951–07100)Handle 100
09960–10010Variable Pin Wrench SetPS vane pump
(2C–T, 2C–TE and 1CD–FTV
engines)
(09962–01000)Variable Pin Wrench Arm Assy
(09963–01000)Pin 10

PP281–01
PP–16
– PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
SUPPLEMENTAL RESTRAINT SYSTEM
SST (Special Service Tools)
09082–00700SRS Airbag Deployment Tool
09082–00750Airbag Deployment Wire
Sub–harness No.3Side airbag assembly
Curtain shield airbag assembly
09843–18020Diagnosis Check Wire

PP284–01
– PREPARATIONBODY
PP–21
SSM (Special Service Materials)
08833–00030Three cement black or equivalent
08850–00801Windshield Glass Adhesive Set
or equivalent

PP285–01
PP–22
– PREPARATIONAIR CONDITIONING
AIR CONDITIONING
SST (Special Service Tools)
07110–58060Air Conditioner Service Tool Set
(07117–58060)Refrigerant Drain Service Valve
(07117–58070)T–Joint
(07117–58080)Quick Disconnect AdapterHigh pressure side
(07117–58090)Quick Disconnect AdapterLow pressure side
(07117–88060)Refrigerant Charging HoseHigh pressure side
(Color: Red)
(07117–88070)Refrigerant Charging HoseLow pressure side
(Color: Blue)
(07117–88080)Refrigerant Charging HoseUtility
(Color: Green)

SERVICE SPECIFICATIONS
STANDARD BOLT SS–1. . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE (E251) SS–4. . . . . . . . . . . . .
SUSPENSION AND AXLE SS–9. . . . . . . . . . . . . . . .
BRAKE SS–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING SS–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM SS–15. . .
BODY ELECTRICAL SS–16. . . . . . . . . . . . . . . . . . . . .
BODY SS–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING SS–19. . . . . . . . . . . . . . . . . . . . .
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. RM599E)
NOTE: The above pages contain only the points which differ
from the above listed manual.

SS0ZS–01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess BoltStud Bolt Weld BoltClass
4T
5T
6T
7T
8T
9T
10T
11 T
No Mark
w/ WasherNo MarkNo Mark
w/ Washer
– SERVICE SPECIFICATIONSSTANDARD BOLT
SS–1
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH

SS0ZT–01
SS–2
– SERVICE SPECIFICATIONSSTANDARD BOLT
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHexagon flange boltmmmmN·mkgf·cmft·lbfN·mkgf·cmft·lbf
4T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 555
130
260
480
760
1,15048 in.·lbf
9
19
35
55
836
14
29
53
84
–60
145
290
540
850
–52 in.·lbf
10
21
39
61
–
5T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
14065
160
330
600
930
1,40056 in.·lbf
12
24
43
67
1017.5
17.5
36
65
100
–75
175
360
670
1,050
–65 in.·lbf
13
26
48
76
–
6T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
17080
195
400
730
1,100
1,75069 in.·lbf
14
29
53
80
1279
21
44
80
125
–90
210
440
810
1,250
–78 in.·lbf
15
32
59
90
–
7T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.510.5
25
52
95
145
23011 0
260
530
970
1,500
2,3008
19
38
70
108
16612
28
58
105
165
–120
290
590
1,050
1,700
–9
21
43
76
123
–
8T
8
10
121.25
1.25
1.2529
61
11 0300
620
1,10022
45
8033
68
120330
690
1,25024
50
90
9T
8
10
121.25
1.25
1.2534
70
125340
710
1,30025
51
9437
78
140380
790
1,45027
57
105
10T
8
10
121.25
1.25
1.2538
78
140390
800
1,45028
58
10542
88
155430
890
1,60031
64
11 6
11 T
8
10
121.25
1.25
1.2542
87
155430
890
1,60031
64
11 647
97
175480
990
1,80035
72
130

SS0ZU–01
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut
Cold Forging Nut Cutting Processed NutClass
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N Old Standard Hexagon Nut
No Mark (w/ Washer)No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
– SERVICE SPECIFICATIONSSTANDARD BOLT
SS–3
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

SS0G6–02
SS–4
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
MANUAL TRANSAXLE (E251)
SERVICE DATA
Input shaft
3rd & 4th gear journal diameter Min.
5th gear journal diameter Min.
Runout Max.
35.950 mm (1.4154 in.)
27.950 mm (1.1004 in.)
0.05 mm (0.0020 in.)
Output shaft
1st gear journal diameter Min.
2nd gear journal diameter Min.
Runout Max.
37.526 mm (1.4774 in.)
34.512 mm (1.3588 in.)
0.06 mm (0.0024 in.)
Oil pump clearance
Rotor body STD
Max.
Rotor tip STD
Max.
Rotor side STD
Max.
0.10 – 0.16 mm (0.0039 – 0.0063 in.)
0.30 mm (0.0118 in.)
0.08 – 0.15 mm (0.0031 – 0.0059 in.)
0.30 mm (0.0118 in.)
0.03 – 0.08 mm (0.0012 – 0.0031 in.)
0.15 mm (0.0059 in.)
Gear thrust clearance
1st & 3rd STD
Max.
2nd STD
Max.
4th STD
Max.
5th STD
Max.
0.10 – 0.35 mm (0.0039 – 0.0138 in.)
0.40 mm (0.0157 in.)
0.10 – 0.45 mm (0.0039 – 0.0177 in.)
0.50 mm (0.0197 in.)
0.10 – 0.55 mm (0.0039 – 0.0217 in.)
0.60 mm (0.0236 in.)
0.10 – 0.57 mm (0.0039 – 0.0224 in.)
0.65 mm (0.0256 in.)
Gear radial clearance
1st & 4th STD
2nd & 3rd STD
5th STD
1st, 2nd, 3rd, 4th & 5th Max.
0.009 – 0.051 mm (0.0004 – 0.0020 in.)
0.009 – 0.053 mm (0.0004 – 0.0021 in.)
0.009 – 0.050 mm (0.0004 – 0.0020 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance
1st, 4th & 5th Min.
2nd & 3rd Min.
0.8 mm (0.031 in.)
0.7 mm (0.028 in.)
Drive in depth
Control shaft cover oil seal
Select inner lever slotted spring pin
No.1 shift inner lever slotted spring pin
No.2 shift inner lever slotted spring pin
0 – 1.0 mm (0 – 0.039 in.)
0
0.5 mm (0
0.020 in.)
0
0.5 mm (0
0.020 in.)
0
0.5 mm (0
0.020 in.)
Input shaft snap ring thickness Mark
No.2 clutch hub H
J
K
L
M
N
P
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)