sensor TOYOTA AVENSIS 1999 Supplement

   








H11831
Airbag
Sensor
Assembly
DTC 88
E1 Tc Check Connector→ ← Curtain
Shield
Airbag
Squib (LH)
ICL+
ICL–ACC
orON
DI–32
– DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
OK
3 Check airbag sensor assembly.
PREPARATION:
(a) Connect the connector to the airbag sensor assembly.
(b) Using a service wire, connect ICL+ and ICL– of the con-
nector (on the curtain shield airbag assembly side) be-
tween the curtain shield airbag assembly (LH) and airbag
sensor assembly.
(c) Connect negative (–) terminal cable to the battery, and
wait at least for 2 seconds.
CHECK:
(a) Turn ignition switch to ACC or ON and wait at least for 20
seconds.
(b) Clear DTC stored in memory.
(See page DI–153 of Pub. No. RM599E)
(c) Turn ignition switch to LOCK, and wait at least for 20 se-
conds.
(d) Turn ignition switch to ACC or ON, and wait at least for 20
seconds.
(e) Check DTC.
(See page DI–152 of Pub. No. RM599E)
OK:
DTC 88 is not output.
HINT:
Codes other than code 88 may be output at this time, but they
are not relevant to this check.
NG Replace airbag sensor assembly.
OK

  





H11832
→←
E1Tc ACC ON
orAirbag
Sensor
Assembly
DTC 88 Check ConnectorCurtain
Shield
Airbag
Squib (LH)
– DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DI–33
4 Check curtain shield airbag squib (LH).
PREPARATION:
(a) Turn ignition switch to LOCK.
(b) Disconnect negative (–) terminal cable from the battery,
and wait at least for 90 seconds.
(c) Connect the curtain shield airbag assembly (LH) connec-
tor.
(d) Connect negative (–) terminal cable to the battery, and
wait at least for 2 seconds.
CHECK:
(a) Turn ignition switch to ACC or ON, and wait at least for 20
seconds.
(b) Clear DTC stored in memory.
(See page DI–153 of Pub. No. RM599E)
(c) Turn ignition switch to LOCK, and wait at least for 20 se-
conds.
(d) Turn ignition switch to ACC or ON, and wait at least for 20
seconds.
(e) Check DTC.
(See page DI–152 of Pub. No. RM599E)
OK:
DTC 88 is not output.
HINT:
Codes other than code 88 may be output at this time, but they
are not relevant to this check.
NG Replace curtain shield airbag assembly (LH).
OK
From the results of the above inspection, the malfunctioning part can now be considered normal.
To make sure of this, use the simulation method to check.

MX096–02
D06619
Starter
39 (400, 29)
Clutch Release
Cylinder
and Line
12 (120, 9)
4.9 (50, 43 in.·lbf)
12 (120, 9)
Control CableClip
Clip
Washer Air Flow Meter
ConnectorAir Cleaner Case
Assembly
with Air Hose
52 (530, 38)
87 (890, 64)
Engine Left
Mounting Bracket
Battery
Tray
No.1 Air Tube Assembly
Diesel Throttle Body
with No.2 Air Tube Assembly
Stay
VSV Connector for EGR
Turbo Pressure
Sensor Connector
Intake Air Temperature
Sensor Connector
Throttle Full
Switch Connector
Throttle Control
Motor Connector

Gasket

Non–reusable part
21 (214, 15)
N·m (kgf·cm, ft·lbf): Specified torque
15 (153, 11)
25 (255, 18)
25 (255, 18)
25 (255, 18)
25 (255, 18)
MX–2
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MANUAL TRANSAXLE UNIT
COMPONENTS

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

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)

MX098–01
D06620
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Lever Housing
Support Bracket
Boot
Clutch Release
Line Bracket
Transaxle Case
Transmission
Oil Cooler
Sub–AssemblyElbow

O–Ring Vehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
PipeMagnet
Transmission
Oil Pipe

Output Shaft Cover
Tapered Roller Bearing
Outer Race

Front Oil Seal
Input Shaft Front
BearingTransmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
17 (175, 13)
47 (480, 35)
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
Gasket



17 (175, 13)
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–9
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

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.

MX060–02
D06656
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer

Tapered Roller Bearing
and Outer Race
Differential Right Case Vehicle Speed Sensor Drive Gear
Differential Left Case

Tapered Roller Bearing
and Outer Race Ring Gear
Oil Baffle

Oil Seal x16
Shim
Oil Seal
63 (640, 46)
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable partx16
124 (1,260, 91)
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–41
DIFFERENTIAL CASE
COMPONENTS

MX09A–01
Q05166
SST
D06654
Matchmarks
MX–42
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
DISASSEMBLY
NOTICE:
When working with FIPG material, you must observe the follow-
ing items.
Using a razor blade and gasket scraper, remove all the old
FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose
material.
Clean both sealing surfaces with a non–residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along
the sealing surface.
Parts must be assembled within 10 minutes of application.
Otherwise, the FIPG material must be removed and reap-
plied.
1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950–40011
2. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
FROM DIFFERENTIAL RIGHT CASE
3. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap the ring gear and remove it.
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the differential right and left cases.
(b) Using a torx wrench (T50), remove the 16 torx screws.
(c) Using a plastic hammer, tap the differential left case.