service 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

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)

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.

IN0EA–01
BO4111
Negative Cable
– INTRODUCTIONFOR ALL OF VEHICLES
IN–9
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The AVENSIS/ CORONA is equipped with an SRS (Sup-
plemental Restraint System), such as the driver airbag,
front passenger airbag, side airbags, curtain shield airbag
and seat belt pretensioners.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the battery (See Pub. No. RM599E,
page DI–152).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (–) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back–up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (–) terminal cable from the battery, the SRS
may deploy.)
When the negative (–) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back–up power supply from out-
side the vehicle.

IN00Z–24
IN–18– INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the AVENSIS/CORONA. In general, the ECU con-
trolled system is considered to be a very intricate system requiring a high level of technical knowledge and
expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, trouble-
shooting of these systems is not complex. If you have adequate understanding of the system and a basic
knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the
problem. This manual is designed through emphasis of the above standpoint to help service technicians
perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled sys-
tems:
The troubleshooting procedure and how to make use of it are described on the following pages.
SystemPage
Supplemental Restraint SystemDI–1
FOR USING HAND–HELD TESTER
Before using the hand–held tester, the hand–held tester’s operator manual should be read thoroughly.
If the hand–held tester cannot communicate with ECU controlled systems when you have connected
the cable of the hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis
data link line (Busline) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s
Manual.

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