rear TOYOTA AVENSIS 1999 Supplement

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.

IN040–02
B02394
Front
JACK POSITION
PANTOGRAPH JACK POSITION
SUPPORT POSITIONFront
RearFront center member
Rear suspension member
CAUTION : When jacking–up the rear and front, make sure the car is not
carrying any extra weight.
Safety stand and swing arm type lift
– INTRODUCTIONREPAIR INSTRUCTIONS
IN–7
VEHICLE LIFT AND SUPPORT LOCATIONS

B02395
PLATE TYPE LIFT
HINT :

Attachment
AB
Left and right set position Place the vehicle over the center of the lift.
Front and rear set positionAlign the cushion gum ends of the plate
with the attachment lower ends (A, C).
Align the attachment upper end (B) with the
front jack supporting point
Attachment dimensions
85 mm (3.35 in)
70 mm (2.76 in)
200 mm (7.87 in) 100 mm (3.94 in)C
(
). 
IN–8
– INTRODUCTIONREPAIR INSTRUCTIONS


B02390
HEAT METHOD: When the problem seems to occur when the suspect area is heated. 2
NOTICE:3 WATER SPRINKLING METHOD:
(1)
(2)
4 OTHER: When a malfunction seems to occur when electrical load is excessive.When the malfunction seems to occur on a rainy day or in a
high–humidity condition. Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.ON HINT:
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
Do not heat to more than 60 C (140 F). (Temperature
is limited not to damage the components.)
Do not apply heat directly to parts in the ECU. (1)
(2)
Never sprinkle water directly into the engine compart-
ment, but indirectly change the temperature and hu-
midity by applying water spray onto the radiator front
surface.
Never apply water directly onto the electronic compo-
nents. NOTICE: IN–24
– INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

FI7187
IN0379
Sensor Side
ECU Side
IN0378
Sensor SideECU Side
IN0380
Sensor SideECU Side
IN0381
Pull Lightly
Looseness of Crimping
IN–30– INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
2. CONNECTOR HANDLING
When inserting tester probes into a connector, insert them from
the rear of the connector. When necessary, use mini test leads.
For water resistant connectors which cannot be accessed from
behind, take good care not to deform the connector terminals.
3. CONTINUITY CHECK (OPEN CIRCUIT CHECK)
(a) Disconnect the connectors at both ECU and sensor
sides.
(b) Measure the resistance between the applicable terminals
of the connectors.
Resistance: 1 Ω or less
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
4. RESISTANCE CHECK (SHORT CIRCUIT CHECK)
(a) Disconnect the connectors on both ends.
(b) Measure the resistance between the applicable terminals
of the connectors and body ground. Be sure to carry out
this check on the connectors on both ends.
Resistance: 1 MΩ or higher
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
5. VISUAL CHECK AND CONTACT PRESSURE CHECK
(a) Disconnect the connectors at both ends.
(b) Check for rust or foreign material, etc. in the terminals of
the connectors.
(c) Check crimped portions for looseness or damage and
check that the terminals are secured in lock portion.
HINT:
The terminals should not come out when pulled lightly from the
back.

– INTRODUCTIONTERMS
IN–35
FFFront–Engine Front–Wheel–Drive
FIPGFormed In Place Gasket
FLFusible Link
FrFront
FRFront–Engine Rear–Wheel–Drive
FWDFront–Wheel–Drive
GNDGround
H/BHatchback
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HTHard Top
HWSHeated Windshield System
IACIdle Air Control
IFSIndependent Front Suspension
IGIgnition
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft–Hand
LHDLeft–Hand Drive
LOLow
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPIMultipoint Electronic Fuel Injection
MPXMultiplex Communication System
M/TManual Transmission
NNeutral
No.Number
O2SOxygen Sensor
O/DOverdrive
OPTOption
P & BVProportioning And Bypass Valve
PCSPower Control System

IN–36
– INTRODUCTIONTERMS
PKB
Parking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take–Off
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight–Hand
RHDRight–Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRRear–Engine Rear–Wheel Drive
RRSRigid Rear Suspension
RWDRear–Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SPECSpecification
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TFTToyota Free–Tronic
T/MTransmission
TMCTOYOTA Motor Corporation
TRCTraction Control System
U/DUnderdrive
VENTVentilator
VINVehicle Identification Number
VSCVehicle Skid Control Vehicle Stability Control
VSVVacuum Switching Valve
w/With
WGNWagon
W/HWire Harness
w/oWithout
1stFirst

PP27T–01
– PREPARATIONMANUAL TRANSAXLE (E251)
PP–1
MANUAL TRANSAXLE (E251)
SST (Special Service Tools)
09223–15020Oil Seal & Bearing ReplacerDifferential case oil seal
09308–00010Oil Seal PullerOutput shaft front bearing outer
race
09316–20011Transfer Bearing ReplacerDifferential case tapered roller
bearing
09316–60011Transmission & Transfer Bearing
Replacer
(09316–00011)Replacer Pipe
(09316–00021)Replacer ”A”
(09316–00041)Replacer ”C”1st gear
No.1 hub sleeve
Differential case tapered roller
bearing outer race
(09316–00071)Replacer ”F”Output shaft front bearing
09506–30012Differential Drive Pinion Rear
Bearing Cone ReplacerOutput shaft rear bearing
09506–35010Differential Drive Pinion Rear
Bearing ReplacerNo.2 hub sleeve
3rd gear
Input shaft rear bearing
1st gear bearing inner race
09608–00081Differential Side Bearing Cone
ReplacerInput shaft oil seal
09612–65014Steering Worm Bearing PullerInput shaft bearing
Differential case tapered roller
bearing outer race

SS–6
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
Output shaft bearing preload (at starting)
New bearing
Reused bearing
0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)
0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)
Output shaft rear bearing adjusting shim thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
1.30 mm (0.0512 in.)
1.35 mm (0.0531 in.)
1.40 mm (0.0551 in.)
1.45 mm (0.0571 in.)
1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
1.80 mm (0.0709 in.)
1.85 mm (0.0728 in.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
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.)

SS0G7–04
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
SS–7
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transaxle upper side x Engine Bolt A
Bolt B64
29650
29647
21
Transaxle lower side x Engine Bolt A
Bolt B
Bolt C
Bolt D
Bolt E40
40
8
20
46408
408
82
204
47030
30
71 in.·lbf
15
34
Diesel throttle body x Engine unit2121415
No.1 air tube assembly x Engine unit2525518
Diesel throttle body with No.2 air tube assembly x Engine unit2525518
Engine front mounting x Engine front mounting bracket8789064
Engine front mounting x Transaxle6465047
Engine rear mounting x Engine rear mounting bracket981,00072
Engine rear mounting x Transaxle6465047
Starter x Starter wire1515311
Starter x Transaxle3940029
Transaxle case protector x Transaxle2525018
Clutch release cylinder x Clutch housing121209
Clutch line bracket x Transaxle Bolt A
(See page MX–4) Bolt B12
4.9120
509
43 in.·lbf
Engine left mounting x Bracket8789064
Engine left mounting Bracket x Transaxle5253038
Front wheel1031,05076
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe4849035
Engine rear mounting x Center member7374054
Engine rear mounting bracket x Body6465047
Engine rear mounting bracket x Engine rear mounting8789064
Engine front mounting x Center member5254038
Engine front mounting bracket x Transaxle6465047
Engine front mounting bracket x Engine front mounting8789064
Front transport hook x Center member3940029
Engine mounting center member x Body7374054
Transaxle case protector x Transaxle2525018
No.2 selecting bellcrank with selecting bellcrank support2020014
Shift and select lever shaft lock bolt4950036
Shift and select lever shaft assembly x Transmission case2020014
Transmission case cover x Transmission case2930022
Breather plug4950036
Output shaft lock nut1231,25090
Shift fork and shift head set bolt2424017
Rear bearing retainer x Transmission case4243031
Straight screw plug2525018
Straight screw plug (Reverse restrict pin)131309
Reverse idler gear shaft lock bolt2930022