SERVICE SPECIFICATIONS for Your Toyota Avensis 4 Door First Generation (1997-2003)

SERVICE SPECIFICATIONS  
STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . .  
SS–1  
SS–4  
SS–6  
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
MANUAL TRANSAXLE (C50, C250) . . . . . . . .  
MANUAL TRANSAXLE (E351) . . . . . . . . . . . . . SS–10  
MANUAL TRANSAXLE (S54, S55) . . . . . . . . . SS–15  
AUTOMATIC TRANSAXLE (A246E) . . . . . . . . SS–19  
AUTOMATIC TRANSAXLE (U240E) . . . . . . . . SS–23  
SUSPENSION AND AXLE . . . . . . . . . . . . . . . . SS–27  
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS–29  
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS–30  
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS–32  
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . SS–33  
REFER TO FOLLOWING REPAIR MANUALS:  
ManualName  
Pub. No.  
RM599E  
AVENSIS/CORONA Chassis and Body Repair Manual  
AVENSIS/CORONA Chassis and Body Repair Manual  
Supplement(Aug.,1999)  
RM698E  
NOTE: The above pages contain only the points which differ  
from the above listed manuals.  
SS–1  
SERVICE SPECIFICATIONS  
–
STANDARD BOLT  
STANDARD BOLT  
SS0ZS–01  
HOW TO DETERMINE BOLT STRENGTH  
Bolt Type  
HexagonHeadBolt  
Stud Bolt  
Class  
Weld Bolt  
Normal Recess Bolt  
Deep Recess Bolt  
4T  
5T  
6T  
4
No Mark  
No Mark  
No Mark  
5
6
w/ Washer  
w/ Washer  
7
8
9
7T  
8T  
9T  
10T  
11T  
10  
11  
B06431  
AVENSIS/CORONA SUP (RM781E)  
SS–2  
SERVICE SPECIFICATIONS  
–
STANDARD BOLT  
SS0ZT–01  
SPECIFIED TORQUE FOR STANDARD BOLTS  
Specifiedtorque  
Diameter  
mm  
Pitch  
mm  
Class  
Hexagon head bolt  
kgf·cm  
Hexagonflangebolt  
kgf·cm  
N·m  
ft·lbf  
N·m  
ft·lbf  
6
1
5
55  
130  
260  
480  
760  
1,150  
48in.·lbf  
6
60  
145  
290  
540  
850  
–
52in.·lbf  
8
1.25  
1.25  
1.25  
1.5  
12.5  
26  
9
14  
29  
53  
84  
–
10  
21  
39  
61  
–
10  
12  
14  
16  
19  
35  
55  
83  
4T  
47  
74  
1.5  
115  
6
1
6.5  
15.5  
32  
65  
160  
330  
600  
930  
1,400  
56in.·lbf  
12  
7.5  
17.5  
36  
75  
175  
360  
670  
1,050  
–
65in.·lbf  
8
1.25  
1.25  
1.25  
1.5  
13  
26  
48  
76  
–
10  
12  
14  
16  
24  
5T  
6T  
7T  
59  
43  
65  
91  
67  
100  
–
1.5  
140  
101  
6
1
8
80  
69in.·lbf  
14  
9
21  
44  
80  
125  
–
90  
210  
440  
810  
1,250  
–
78in.·lbf  
8
1.25  
1.25  
1.25  
1.5  
19  
195  
15  
32  
59  
90  
–
10  
12  
14  
16  
39  
400  
29  
71  
730  
53  
110  
170  
1,100  
1,750  
80  
1.5  
127  
6
1
10.5  
25  
110  
260  
8
12  
28  
120  
290  
590  
1,050  
1,700  
–
9
21  
43  
76  
123  
–
8
1.25  
1.25  
1.25  
1.5  
19  
10  
12  
14  
16  
52  
530  
38  
58  
95  
970  
70  
105  
165  
–
145  
230  
1,500  
2,300  
108  
166  
1.5  
8
1.25  
1.25  
1.25  
29  
61  
300  
620  
22  
45  
80  
33  
68  
330  
690  
24  
50  
90  
8T  
9T  
10  
12  
110  
1,100  
120  
1,250  
8
1.25  
1.25  
1.25  
34  
70  
340  
710  
25  
51  
94  
37  
78  
380  
790  
27  
57  
10  
12  
125  
1,300  
140  
1,450  
105  
8
1.25  
1.25  
1.25  
38  
78  
390  
800  
28  
58  
42  
88  
430  
890  
31  
64  
10T  
11T  
10  
12  
140  
1,450  
105  
155  
1,600  
116  
8
1.25  
1.25  
1.25  
42  
87  
430  
890  
31  
64  
47  
97  
480  
990  
35  
72  
10  
12  
155  
1,600  
116  
175  
1,800  
130  
AVENSIS/CORONA SUP (RM781E)  
SS–3  
SERVICE SPECIFICATIONS  
–
STANDARD BOLT  
SS0ZU–01  
HOW TO DETERMINE NUT STRENGTH  
Nut Type  
OldStandardHexagonNut  
Present Standard  
Hexagon Nut  
Class  
4N  
Cold Forging Nut  
Cutting Processed Nut  
No Mark  
5N (4T)  
No Mark (w/ Washer)  
No Mark (w/ Washer)  
No Mark  
6N  
6N  
7N (5T)  
*
8N  
10N (7T)  
11N  
8N  
10N  
No Mark  
11N  
12N  
12N  
*: Nut with 1 or more marks on one side surface of the nut.  
B06432  
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  
AVENSIS/CORONA SUP (RM781E)  
SS–4  
SERVICE SPECIFICATIONS  
–
CLUTCH  
CLUTCH  
SS02L–03  
SERVICE DATA  
Pedalheight from asphalt sheet  
3ZZ–FE LHD 139.7 – 149.7 mm (5.500 – 5.894 in.)  
RHD 144.3 – 154.3 mm (5.681 – 6.075 in.)  
1ZZ–FE Engine LHD 139.7 – 149.7 mm (5.500 – 5.894 in.)  
RHD 144.3 – 154.3 mm (5.681 – 6.075 in.)  
1AZ–FSE Engine LHD 148.3 – 158.3 mm (5.893 – 6.232 in.)  
RHD 152.9 – 162.9 mm (6.020 – 6.413 in.)  
Pedalfreeplay  
1.0 – 5.0 mm (0.039 – 0.197 in.)  
5.0 – 15.0 mm (0.197 – 0.591 in.)  
25 mm (0.98 in.) or more  
Push rod play at pedal top  
Clutch release point from pedal full stroke end position  
Disc rivet head depth  
Min. 0.3 mm (0.012 in.)  
Disc runout  
Max. 0.8 mm (0.031 in.)  
Flywheelrunout  
Max 0.1 mm (0.004 in.)  
Diaphragm spring finger wear  
Diaphragm spring finger wear  
Diaphragmspringtipnon–alignment  
Max. depth 0.5 mm (0.020 in.)  
Max. width 6.0 mm (0.236 in.)  
Max. 0.5 mm (0.020 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–5  
SERVICE SPECIFICATIONS  
–
CLUTCH  
SS02M–03  
TORQUE SPECIFICATION  
Parttightened  
N·m  
15  
kgf·cm  
155  
ft·lbf  
11  
Clutch line union  
Master cylinder installation nut  
12  
120  
9
Master cylinder x Clutch accumulator  
Clutch cover x Flywheel  
1CD–FTV Engine RHD  
32 (44)  
19  
330 (450)  
195  
24 (33)  
14  
Release fork support  
1ZZ–FE, 3ZZ–FEEngine  
OthersEngine  
37  
39  
375  
400  
27  
29  
( ): For use without SST  
AVENSIS/CORONA SUP (RM781E)  
SS–6  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
MANUAL TRANSAXLE (C50, C250)  
SS02P–06  
SERVICE DATA  
Inputshaft roller bearing journal diameter  
Input shaft 3rd gear journal diameter  
Input shaft 4th gear journal diameter  
Input shaft 5th gear journal diameter  
Input shaft runout  
Min. 24.985 mm (0.9834 in.)  
Min. 30.985 mm (1.2199 in.)  
Min. 28.985mm(1.1411 in.)  
Min. 24.885 mm (0.9797 in.)  
Max. 0.03 mm (0.0012 in.)  
Min. 32.985 mm (1.2986 in.)  
Min. 37.985 mm (1.4955 in.)  
Min. 31.985 mm (1.2592 in.)  
Max. 0.03 mm (0.0012 in.)  
Output shaft roller bearing journal diameter  
Output shaft 1st gear journal diameter  
Output shaft 2nd gear journal diameter  
Output shaft runout  
Gear thrust clearance 1st  
STD 0.10 – 0.40 mm (0.0039 – 0.0157 in.)  
Max. 0.40 mm (0.0157 in.)  
Gear thrust clearance 2nd  
STD 0.10 – 0.45 mm (0.0039 – 0.0177 in.)  
Max. 0.45 mm (0.0177 in.)  
Gear thrust clearance 3rd  
STD 0.10 – 0.35 mm (0.0039 – 0.0138 in.)  
Max. 0.35 mm (0.0138 in.)  
Gear thrust clearance 4th  
STD 0.10 – 0.55 mm (0.0039 – 0.0217 in.)  
Max. 0.55 mm (0.0022 in.)  
Gear thrust clearance 5th  
STD 0.10 – 0.57 mm (0.0039 – 0.0244 in.)  
Max. 0.57 mm (0.0224 in.)  
Gear radial clearance 1st, 2nd, 3rd, 4th, and 5th (KOYO made)  
Gear radial clearance 1st, 2nd, 3rd, 4th, and 5th (NSK made)  
STD 0.015 – 0.058 mm (0.0006 – 0.0023 in.)  
Max. 0.058 mm (0.0023 in.)  
STD 0.015 – 0.056 mm (0.0006 – 0.0022 in.)  
Max. 0.056 mm (0.0022 in.)  
No. 3 gear shift fork to No. 3 hub sleeve clearance  
No. 2 gear shift fork to No. 2 hub sleeve clearance  
No. 1 gear shift fork to reverse gear clearance  
Synchronizer ring to gear clearance 1st, 4th and 5th  
Max. 0.5 mm (0.020 in.)  
Max. 0.35 mm (0.014 in.)  
Max. 0.35 mm (0.014 in.)  
Min. 0.75 mm (0.0295 in.)  
Min. 0.65 mm (0.0256 in.)  
Min. 0.70 mm (0.0276 in.)  
Synchronizer ring to gear clearance  
Synchronizer ring to gear clearance  
3rd  
2nd  
Drive in depth  
Control shaft cover oil seal  
Transmission case oil seal  
Transaxle case oil seal  
Select inner lever slotted spring pin  
1.0 – 2.0 mm (0.039 – 0.079 in.)  
9.9 ± 0.3 mm (0.390 ± 0.012 in.)  
1.9 ± 0.3 mm (0.075 ± 0.012 in.)  
0 ± 0.5 mm (0 ± 0.020 in.)  
No.1 shift inner lever slotted spring pin  
No.2 shift inner lever slotted spring pin  
0 ± 0.5 mm (0 ± 0.020 in.)  
3.5 ± 0.5 mm (0.138 ± 0.020 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–7  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
Input shaft snap ring thickness  
No.2 clutch hub  
Mark 0 2.30 mm (0.0906 in.)  
Mark 1 2.36 mm (0.0929 in.)  
Mark 2 2.42 mm (0.0953 in.)  
Mark 3 2.48 mm (0.0976 in.)  
Mark 4 2.54 mm (0.1000 in.)  
Mark 5 2.60 mm (0.1024 in.)  
Mark A 2.29 mm (0.0902 in.)  
Mark B 2.35 mm (0.0925 in.)  
Mark C 2.41 mm (0.0949 in.)  
Mark D 2.47 mm (0.0972 in.)  
Mark E 2.53 mm (0.0996 in.)  
Mark F 2.59 mm (0.1020 in.)  
Rear bearing  
Output shaft snap ring thickness  
No.1 clutch hub  
Mark A 2.50 mm (0.0984 in.)  
Mark B 2.56 mm (0.1008 in.)  
Mark C 2.62 mm (0.1031 in.)  
Mark D 2.68 mm (0.1055 in.)  
Mark E 2.74 mm (0.1079 in.)  
Mark F 2.80 mm (0.1102 in.)  
Mark A 2.25 mm (0.0886 in.)  
Mark B 2.31 mm (0.0909 in.)  
Mark C 2.37 mm (0.0933 in.)  
Mark D 2.43 mm (0.0957 in.)  
Mark E 2.49 mm (0.0980 in.)  
Mark F 2.55 mm (0.1004 in.)  
Mark G 2.61 mm (0.1028 in.)  
No.3 clutch hub  
Differential side bearing preload (at starting)(For use with SST)  
Newbearing 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)  
Reusedbearing 0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)  
Differential pinion to side gear backlash  
0.05 mm – 0.20 mm (0.0020 – 0.0079 in.)  
Differential side gear thrust washer thickness  
0.95 mm (0.0374 in.)  
1.00 mm (0.0394 in.)  
1.05 mm (0.0413 in.)  
1.10 mm (0.0433 in.)  
1.15 mm (0.0453 in.)  
1.20 mm (0.0472 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–8  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
Differential side bearing adjusting shim thickness  
Mark A 2.10 mm (0.0827 in.)  
Mark B 2.15 mm (0.0846 in.)  
Mark C 2.20 mm (0.0866 in.)  
Mark D 2.25 mm (0.0886 in.)  
Mark E 2.30 mm (0.0906 in.)  
Mark F 2.35 mm (0.0925 in.)  
Mark G 2.40 mm (0.0945 in.)  
Mark H 2.45 mm (0.0965 in.)  
Mark J 2.50 mm (0.0984 in.)  
Mark K 2.55 mm (0.1004 in.)  
Mark L 2.60 mm (0.1024 in.)  
Mark M 2.65 mm (0.1043 in.)  
Mark N 2.70 mm (0.1063 in.)  
Mark P 2.75 mm (0.1083 in.)  
Mark Q 2.80 mm (0.1102 in.)  
Mark R 2.85 mm (0.1122 in.)  
Mark S 2.90 mm (0.1142 in.)  
Mark T 2.95 mm (0.1161 in.)  
Mark U 3.00 mm (0.1181 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–9  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
SS02Q–07  
TORQUE SPECIFICATION  
Parttightened  
N·m  
12  
kgf·cm  
ft·lbf  
9
Clutch release cylinder x Transaxle  
120  
400  
650  
Starter x Transaxle  
39  
29  
47  
Transaxle x Engine  
64  
Stiffener plate set bolt (See page MX–3)  
Bolt B  
Bolt A  
47  
23  
480  
230  
35  
17  
Engine left mounting bracket x Transaxle  
Bolt A  
Nut B  
52  
87  
530  
890  
38  
64  
Frontwheel  
216  
39  
62  
43  
39  
2,200  
400  
630  
440  
400  
159  
29  
46  
32  
29  
Filler and Drain plugs  
Front exhaust pipe x Exhaust manifold  
Center exhaust pipe x Tail exhaust pipe  
Front transport hook x Engine mounting center member  
Engine mounting center member (See page MX–3)  
Bolt A  
Bolt B  
73  
72  
740  
730  
54  
53  
Engine rear mounting bracket x Insulator  
Transmission case x Transaxle case  
Transmission case x Transmission case cover  
Straight screw plug (Reverse restrict pin)  
Straight screw plug  
87  
29  
18  
13  
25  
11  
77  
29  
17  
16  
39  
29  
29  
27  
118  
20  
12  
25  
12  
17  
25  
40  
11  
37  
890  
300  
185  
130  
250  
115  
790  
300  
175  
160  
400  
300  
300  
280  
1,200  
200  
120  
250  
120  
175  
250  
410  
115  
375  
64  
22  
13  
9
18  
8
Transaxle case receiver x Transaxle case  
Differential case x Ring gear  
57  
22  
13  
12  
29  
22  
22  
20  
87  
14  
9
Transaxle case x Differentialcase  
Reverse shift arm bracket set bolt  
No.1, No.2, No.3 shift forks and shift head set bolt  
Lock ball assembly (Reverse shift fork side)  
Lock ball assembly (Shift and select lever shaft side)  
Reverse idler gear shaft lock bolt  
Rear bearing retainer x Transmission case  
5th driven gear lock nut  
Control shaft cover x Transmission case  
Control shift lever x Dust boot  
Selecting bellcrank assembly x Transaxle case  
Control shaft assembly x Transaxle case  
Oil receiver pipe set bolt  
18  
9
13  
18  
30  
8
Control cable bracket x Transmission case  
Back–up light switch  
Speed sensor lock plate set bolt  
Clutch release fork support  
27  
AVENSIS/CORONA SUP (RM781E)  
SS–10  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE(E351)  
MANUAL TRANSAXLE (E351)  
SS0G6–06  
SERVICE DATA  
Input shaft  
3rd & 4th gear journal diameter  
5th gear journal diameter  
Runout  
Min. 35.984 mm (1.4167 in.)  
Min. 27.957 mm (1.1007 in.)  
Max. 0.03 mm (0.0012 in.)  
Output shaft  
1st gear journal diameter  
2nd gear journal diameter  
Runout  
Min. 37.610 mm (1.4807 in.)  
Min. 34.502 mm (1.3583 in.)  
Max. 0.03 mm (0.0012 in.)  
Gear thrust clearance  
1st  
Max. 0.40 mm (0.0157 in.)  
Min. 0.25 mm (0.0098 in.)  
Max. 0.35 mm (0.0138 in.)  
Min. 0.10 mm (0.0039 in.)  
Max. 0.57 mm (0.0224 in.)  
Min. 0.10 mm (0.0039 in.)  
Max. 0.65 mm (0.0256 in.)  
Min. 0.10 mm (0.0039 in.)  
2nd & 3rd  
4th  
5th  
Gear radial clearance  
1st, 2nd & 3rd  
MAX. 0.053 mm (0.0021 in.)  
MAX. 0.051 mm (0.0020 in.)  
MAX. 0.050 mm (0.0020 in.)  
4th  
5th  
No.3 shift fork to hub sleeve clearance  
No.2 shift fork to hub sleeve clearance  
No.1 shift fork to hub sleeve clearance  
Max. 0.35 mm (0.014 in.)  
Max. 0.69 mm (0.027 in.)  
Max. 0.35 mm (0.014 in.)  
Synchronizer ring to gear clearance  
1st & 2nd  
3rd  
Min. 0.70 mm (0.028 in.)  
Min. 0.65 mm (0.026 in.)  
Min. 0.75 mm (0.030 in.)  
Min. 1.25 mm (0.049 in.)  
4th  
5th  
Drive in depth  
Control shaft cover oil seal  
Transmission case oil seal  
Transaxle case oil seal  
0 – 1.0 mm (0 – 0.039 in.)  
3.5 ± 0.5 mm (0.138 ± 0.020 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.)  
0 ± 0.5 mm (0 ± 0.020 in.)  
Select inner lever slotted spring pin  
No.1 shift inner lever slotted spring pin  
No.2 shift inner lever slotted spring pin  
Input shaft snap ring thickness  
No.2 clutch hub  
Mark  
H
J
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.)  
K
L
M
N
P
AVENSIS/CORONA SUP (RM781E)  
SS–11  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE(E351)  
Input shaft snap ring thickness  
No.3 clutch hub  
Mark  
a
b
c
d
e
f
1.75 mm (0.0689 in.)  
1.80 mm (0.0709 in.)  
1.85 mm (0.0729 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 (0.0847 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.)  
2.65 mm (0.1043 in.)  
2.70 mm (0.1063 in.)  
g
h
j
Ball bearing  
1
2
3
4
5
6
7
8
Differential pinion to side gear backlash  
STD 0.05 – 0.20 mm (0.0020 – 0.0079 in.)  
Differential side gear thrust washer thickness  
1.00 mm (0.0394 in.)  
1.10 mm (0.0433 in.)  
1.20 mm (0.0472 in.)  
1.30 mm (0.0512 in.)  
Differential case side bearing preload (at starting)  
New bearing (Output shaft preload plus)  
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)  
Reused bearing (Output shaft preload plus)  
Differential side bearing adjusting shim thickness  
Mark  
0
1
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.)  
2.55 mm (0.1004 in.)  
2.60 mm (0.1024 in.)  
2.65 mm (0.1043 in.)  
2.70 mm (0.1063 in.)  
2.75 mm (0.1083 in.)  
2.80 mm (0.1102 in.)  
2.85 mm (0.1122 in.)  
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
AVENSIS/CORONA SUP (RM781E)  
SS–12  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE(E351)  
Output shaft bearing preload (at starting)  
New 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)  
Reused bearing  
Output shaft rear bearing adjusting shim thickness  
Mark  
0
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.)  
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
AVENSIS/CORONA SUP (RM781E)  
SS–13  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE(E351)  
SS0G7–08  
TORQUE SPECIFICATION  
Parttightened  
N·m  
kgf·cm  
ft·lbf  
Transaxle upper side x Engine  
Transaxle lower side x Engine  
Bolt A  
Bolt B  
64  
25  
650  
296  
47  
21  
Bolt A  
Bolt B  
Bolt C  
Bolt D  
Bolt E  
40  
40  
8
408  
408  
82  
30  
30  
71in.·lbf  
15  
20  
46  
204  
470  
34  
Diesel throttle body x Engine unit  
21  
25  
25  
87  
64  
98  
64  
15  
39  
18  
12  
214  
255  
255  
890  
650  
1,000  
650  
153  
400  
185  
120  
15  
18  
18  
64  
47  
72  
47  
11  
29  
13  
9
No.1 air tube assembly x Engine unit  
Diesel throttle body with No.2 air tube assembly x Engine unit  
Engine front mounting x Engine front mounting bracket  
Engine front mounting x Transaxle  
Engine rear mounting x Engine rear mounting bracket  
Engine rear mounting x Transaxle  
Starter x Starter wire  
Starter x Transaxle  
Transmission case protector x Transmission  
Clutch release cylinder x Clutch housing  
Clutch line bracket x Transaxle  
(See page MX–4)  
Bolt A  
Bolt B  
12  
120  
50  
9
4.9  
43in.·lbf  
Engine left mounting x Bracket  
87  
52  
103  
62  
43  
73  
64  
87  
52  
64  
87  
39  
73  
20  
29  
20  
29  
49  
123  
24  
42  
25  
13  
29  
29  
890  
530  
1,050  
630  
440  
740  
650  
890  
540  
650  
890  
400  
740  
200  
300  
200  
300  
500  
1,250  
240  
430  
250  
130  
300  
300  
64  
38  
76  
46  
32  
54  
47  
64  
38  
47  
64  
29  
54  
14  
22  
14  
22  
36  
90  
17  
31  
18  
9
Engine left mounting Bracket x Transaxle  
Frontwheel  
Front exhaust pipe x Exhaust manifold  
Front exhaust pipe x Center exhaust pipe  
Engine rear mounting x Center member  
Engine rear mounting bracket x Body  
Engine rear mounting bracket x Engine rear mounting  
Engine front mounting x Center member  
Engine front mounting bracket x Transaxle  
Engine front mounting bracket x Engine front mounting  
Front transport hook x Center member  
Engine mounting center member x Body  
No.2 selecting bellcrank with selecting bellcrank support  
Lock ball assembly  
Shift and select lever shaft assembly x Transmission case  
Transmission case cover x Transmission case  
Breatherplug  
Output shaft lock nut  
Shift fork and shift head set bolt  
Rear bearing retainer x Transmission case  
Straight screw plug  
Straight screw plug (Reverse restrict pin)  
Reverse idler gear shaft lock bolt  
22  
22  
Transmission case x Transaxle case  
AVENSIS/CORONA SUP (RM781E)  
SS–14  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE(E351)  
Reverse shift arm bracket assembly x Transaxle case  
Transaxle case receiver x Transaxle case  
Clutch release fork support  
17  
7.4  
39  
175  
75  
13  
65in.·lbf  
29  
400  
175  
175  
175  
410  
500  
175  
1,080  
120  
50  
Control cable bracket x Transaxle case  
Vehicle speed sensor  
17  
13  
17  
13  
Clutch release line bracket x Transaxle case  
Back–up light switch  
17  
13  
40  
30  
Filler and drain plugs  
49  
36  
No.1 and No.2 oil receiver pipes x Transmission case  
Ring gear set bolt  
17  
13  
106  
12  
78  
Shift lever assembly x Body  
9
Retainer x Body  
4.9  
4.9  
43in.·lbf  
43in.·lbf  
Grommet retainer x Body  
50  
AVENSIS/CORONA SUP (RM781E)  
SS–15  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (S54, S55)  
MANUAL TRANSAXLE (S54, S55)  
SS09M–04  
SERVICE DATA  
Inputshaft roller bearing journal diameter  
Input shaft 3rd gear journal diameter  
Input shaft 4th gear journal diameter  
Input shaft 5th gear journal diameter  
Input shaft runout  
Min. 29.987 mm (1.181 in.)  
Min. 33.100 mm (1.3031 in.)  
Min. 32.484 mm (1.2789 in.)  
Min. 26.987 mm (1.0625 in.)  
Max. 0.03 mm (0.0012 in.)  
Min. 31.984 mm (1.2592 in.)  
Min. 37.987 mm (1.4956 in.)  
Min. 32.002 mm (1.2599 in.)  
Max. 0.05 mm (0.0020 in.)  
Output shaft roller bearing journal diameter  
Output shaft 1st gear journal diameter  
Output shaft 2nd gear journal diameter  
Output shaft runout  
Gear thrust clearance 1st  
Max. 0.29 mm (0.0114 in.)  
Min. 0.10 mm (0.0039 in.)  
Gear thrust clearance 2nd  
Gear thrust clearance 3rd  
Max. 0.34 mm (0.0134 in.)  
Min. 0.10 mm (0.0039 in.)  
Max. 0.35 mm (0.0138 in.)  
Min. 0.10 mm (0.0039 in.)  
Gear thrust clearance 4th  
Max. 0.45 mm (0.0177 in.)  
Min. 0.10 mm (0.0039 in.)  
Gear thrust clearance 5th  
Max. 0.57 mm (0.0224 in.)  
Min. 0.10 mm (0.0039 in.)  
Gear radial clearance 1st, 2nd, 3rd and 4th  
Gear radial clearance 5th  
Max. 0.051 mm (0.0020 in.)  
Min. 0.009 mm (0.0004 in.)  
Max. 0.048 mm (0.0019 in.)  
Min. 0.009 mm (0.0004 in.)  
Shift fork to hub sleeve clearance  
Max. 0.4 mm ( 0.016 in.)  
Synchronizer ring to gear clearance 1st and 4th  
Synchronizer ring to gear clearance 2nd  
Min. 0.75 mm (0.030 in.)  
Min. 0.7 mm (0.028 in.)  
Synchronizer ring to gear clearance 3rd  
Min. 0.65 mm (0.026 in.)  
Differential case side bearing preload (at starting)(For use with SST)  
Differential pinion to side gear backlash  
1.0 – 1.6 N·m (10 – 16 kgf·cm, 8.7 – 13.9 in.·lbf)  
0.05 – 0.20 mm (0.0020 – 0.0079 in.)  
Drive in depth  
Input shaft front oil seal  
0 – 0.5 mm (0 – 0.020 in.)  
Slotted spring pin for reverse restrict pin  
Shift and select lever shaft slotted spring pin  
13.5 ± 0.5 mm (0.531 ± 0.020 in.)  
23.5 ± 1.0 mm (0.925 ± 0.039 in.)  
Differential side gear thrust washer thickness  
0.95 mm (0.0374 in.)  
1.00 mm (0.0394 in.)  
1.05 mm (0.0413 in.)  
1.10 mm (0.0433 in.)  
1.15 mm (0.0453 in.)  
1.20 mm (0.0472 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–16  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (S54, S55)  
Input shaft snap ring thickness  
No.2 clutch hub  
Mark 1 1.95 – 2.00 mm (0.0768 – 0.0787 in.)  
Mark 2 2.00 – 2.05 mm (0.0787 – 0.0807 in.)  
Mark 3 2.05 – 2.10 mm (0.0807 – 0.0827 in.)  
Mark 4 2.10 – 2.15 mm (0.0827 – 0.0846 in.)  
Mark 5 2.15 – 2.20 mm (0.0846 – 0.0866 in.)  
Mark 6 2.20 – 2.25 mm (0.0866 – 0.0886 in.)  
Mark 13 2.20 – 2.25 mm (0.0866 – 0.0886 in.)  
Mark 14 2.25 – 2.30 mm (0.0886 – 0.0906 in.)  
Mark 15 2.30 – 2.35 mm (0.0906 – 0.0925 in.)  
Mark 16 2.35 – 2.40 mm (0.0925 – 0.0945 in.)  
Mark 17 2.40 – 2.45 mm (0.0945 – 0.0965 in.)  
Mark 18 2.45 – 2.50 mm (0.0965 – 0.0984 in.)  
Mark 19 2.50 – 2.55 mm (0.0984 – 0.01004 in.)  
Mark 20 2.55 – 2.60 mm (0.1004 – 0.01024 in.)  
Mark 21 2.60 – 2.65 mm (0.1024 – 0.01043 in.)  
Mark 22 2.65 – 2.70 mm (0.1043 – 0.01063 in.)  
Mark 23 2.70 – 2.75 mm (0.1063 – 0.01083 in.)  
Mark 24 2.75 – 2.80 mm (0.1083 – 0.01102 in.)  
Mark 25 2.80 – 2.85 mm (0.1102 – 0.01122 in.)  
Mark 26 2.85 – 2.90 mm (0.1122 – 0.01142 in.)  
Mark 27 2.90 – 2.95 mm (0.1142 – 0.01161 in.)  
Mark A 2.15 – 2.20 mm (0.0846 – 0.0866 in.)  
Mark B 2.20 – 2.25 mm (0.0866 – 0.0886 in.)  
Mark C 2.25 – 2.30 mm (0.0886 – 0.0906 in.)  
Mark D 2.30 – 2.35 mm (0.0906 – 0.0925 in.)  
Mark E 2.35 – 2.40 mm (0.0925 – 0.0945 in.)  
No.3 clutch hub  
Rear bearing  
Differential side bearing adjusting shim thickness  
Mark 1 1.90 mm (0.0748 in.)  
Mark 2 1.95 mm (0.0768 in.)  
Mark 3 2.00 mm (0.0787 in.)  
Mark 4 2.05 mm (0.0807 in.)  
Mark 5 2.10 mm (0.0827 in.)  
Mark 6 2.15 mm (0.0846 in.)  
Mark 7 2.20 mm (0.0866 in.)  
Mark 8 2.25 mm (0.0886 in.)  
Mark 9 2.30 mm (0.0906 in.)  
Mark 10 2.35 mm (0.0925 in.)  
Mark 11 2.40 mm (0.0945 in.)  
Mark 12 2.45 mm (0.0965 in.)  
Mark 13 2.50 mm (0.0984 in.)  
Mark 14 2.55 mm (0.1004 in.)  
Mark 15 2.60 mm (0.1024 in.)  
Mark 16 2.65 mm (0.1043 in.)  
Mark 17 2.70 mm (0.1063 in.)  
Mark 18 2.75 mm (0.1083 in.)  
Mark 19 2.80 mm (0.1102 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–17  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (S54, S55)  
SS09N–05  
TORQUE SPECIFICATION  
Parttightened  
N·m  
39  
kgf·cm  
ft·lbf  
29  
9
Starter x Transaxle  
400  
120  
Clutch release cylinder x Transaxle  
12  
Clutch line bracket x Transaxle (See page MX–3)  
Bolt A  
Bolt B  
12  
120  
50  
9
4.9  
43in.·lbf  
Engine left mounting bracket x Transaxle  
Engine left mounting bracket x Insulator  
Transaxle x Engine (See page MX–3)  
52  
87  
530  
890  
38  
64  
Upper bolt  
64  
25  
650  
250  
47  
18  
Stiffener plate x Transaxle (See page MX–3)  
Bolt A  
Bolt B  
43  
21  
440  
210  
32  
15  
Frontwheel  
216  
49  
62  
43  
39  
2,200  
500  
630  
440  
400  
159  
36  
46  
32  
29  
Filler and Drain plugs  
Front exhaust pipe x Exhaust manifold  
Front exhaust pipe x Center exhaust pipe  
Front transport hook x Engine Mounting Center Member  
Engine Mounting Center Member (See page MX–3)  
Bolt A  
Bolt B  
73  
72  
740  
730  
54  
53  
Engine rear mounting bracket x Insulator  
Engine rear mounting bracket x Transaxle  
Intake manifold stay  
87  
64  
44  
12  
4.9  
4.9  
29  
29  
18  
42  
18  
7.4  
123  
18  
29  
37  
6.4  
83  
37  
18  
18  
29  
44  
18  
7.4  
13  
890  
650  
450  
120  
50  
64  
47  
33  
Shift lever assembly x Body  
Shift cable grommet retainer x Body  
Transmission control cable bracket x Body  
Transmission case x Transaxle case  
Transmission case x Case cover  
Transmission case protector  
Rearbearingretainer  
9
43in.·lbf  
43in.·lbf  
22  
50  
300  
300  
185  
430  
185  
75  
22  
13  
31  
Output shaft front bearing lock plate  
Transaxle case receiver set bolt  
5th driven gear lock nut  
13  
65in.·lbf  
90  
1,250  
185  
300  
375  
65  
No.3 shift fork x No.1 shift fork shaft  
Reverse idler shaft lock bolt  
Shift and select lever aseembly  
Control shift lever x Lever shaft  
Ring gear x Differentialcase  
Selecting bellcrank x Transmission case  
Reverse shift arm bracket  
13  
22  
27  
56in.·lbf  
61  
850  
380  
185  
185  
300  
450  
185  
75  
27  
13  
No.3 shift fork x Shift fork shaft  
Lock ball assembly  
13  
22  
Back–up light switch  
33  
Differentialsidebearingretainer  
Releasebearingretainer  
13  
65in.·lbf  
9
Straight screw plug  
130  
AVENSIS/CORONA SUP (RM781E)  
SS–18  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (S54, S55)  
5.4  
Speed sensor lock plate set bolt  
Clutch release fork support  
55  
480  
48in.·lbf  
35  
47  
AVENSIS/CORONA SUP (RM781E)  
SS–19  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(A246E)  
AUTOMATIC TRANSAXLE (A246E)  
SS0YH–02  
SERVICE DATA  
Linepressure (Wheel locked)  
Engineidling  
2
D range 372 – 441 kPa (3.8 – 4.5 kgf/cm , 54 – 64 psi)  
2
R range 598 – 716 kPa (6.1 – 7.3 kgf/cm , 87 – 104 psi)  
at stall (Throttle valve fully opened)  
2
D range 981 – 1,138 kPa (10.0 – 11.6 kgf/cm , 142 – 165 psi)  
2
R range 1,392 – 1,726 kPa (14.2 – 17.6 kgf/cm , 202 – 250 psi)  
Enginestallrevolution  
Time lag  
D and R range 2,500 ± 150 rpm  
N → D range Less than 1.2 seconds  
N → R range Less than 1.5 seconds  
Engine idle speed  
(A/C OFF)  
N range 700 ± 50 rpm  
Drive plate runout  
Max. 0.20 mm (0.0079 in.)  
Max. 0.30 mm (0.0118 in.)  
More than 15.5 mm (0.610 in.)  
Torque converter runout  
Torque converter correct distance  
Differential oil seal drive in depth  
LH side 5.3 ± 0.5 mm (0.209 ± 0.020 in.)  
RH side 3.1 ± 0.5 mm (0.122 ± 0.020 in.)  
LHD  
Shift schedule (NORM mode)  
D range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 120 – 132 km/h (75 – 82 mph)  
3 → 2 64 – 71 km/h (40 – 44 mph)  
2 → 1 20 – 25 km/h (12 – 16 mph)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 146 –159 km/h (91 – 99 mph)  
3 → 2 85 – 93 km/h (53 – 58 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
3 → 4 32 – 38 km/h (20 – 24 mph)  
4 → 3 14 – 20 km/h (9 – 12 mph)  
(Kick–down Switch ON)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 1 38 – 44 km/h (24 – 27 mph)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
(Kick–down Switch ON)  
L range  
(Throttle valve fully opened)  
2 → 1 45 – 51 km/h (28 – 32 mph)  
AVENSIS/CORONA SUP (RM781E)  
SS–20  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(A246E)  
Shift schedule (PWR mode)  
D range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 142 – 155 km/h (88 – 96 mph)  
3 → 2 85 – 93 km/h (53 – 58 mph)  
2 → 1 38 – 44 km/h (24 – 27 mph)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 85 – 93 km/h (53 – 58 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
3 → 4 32 – 38 km/h (20 – 24 mph)  
4 → 3 14 – 20 km/h (9 – 12 mph)  
(Kick–down Switch ON)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 1 38 – 44 km/h (24 – 27 mph)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
(Kick–down Switch ON)  
L range  
(Throttle valve fully opened)  
2 → 1 45 – 51 km/h (28 – 32 mph)  
Shift schedule (SNOW mode)  
D range  
(Throttle valve fully opened)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 120 – 132 km/h (75 – 82 mph)  
3 → 2 64 – 71 km/h (40 – 44 mph)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 85 – 93 km/h (53 – 58 mph)  
3 → 4 32 – 38 km/h (20 – 24 mph)  
4 → 3 14 – 20 km/h (9 – 12 mph)  
(Kick–down Switch ON)  
(Throttle valve fully closed)  
Lock–up point (NORM mode)  
(Throttle valve opening 5%)  
3rd Gear (O/D main switch OFF)  
Lock–up ON 52 – 59 km/h (32 – 37 mph)  
Lock–up OFF 49 – 56 km/h (30 – 35 mph)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 68 km/h (38 – 42 mph)  
O/D gear  
Lock–up point (PWR mode)  
(Throttle valve opening 5%)  
3rd Gear (O/D main switch OFF)  
Lock–up ON 55 – 62 km/h (34 – 39 mph)  
Lock–up OFF 52 – 59 km/h (32 – 37 mph)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 68 km/h (38 – 42 mph)  
O/D gear  
Lock–up point (SNOW mode)  
(Throttle valve opening 5%)  
3rd Gear (O/D main switch OFF)  
Lock–up ON 52 – 59 km/h (32 – 37 mph)  
Lock–up OFF 49 – 56 km/h (30 – 35 mph)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 68 km/h (38 – 42 mph)  
O/D gear  
AVENSIS/CORONA SUP (RM781E)  
SS–21  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(A246E)  
RHD  
Shift schedule (NORM mode)  
D range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 85 – 93 km/h (53 – 58 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
3 → 4 32 – 38 km/h (20 – 24 mph)  
4 → 3 14 – 20 km/h (9 – 12 mph)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
L range  
(Throttle valve fully opened)  
2 → 1 45 – 51 km/h (28 – 32 mph)  
Shift schedule (PWR mode)  
D range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 85 – 93 km/h (53 – 58 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
3 → 4 32 – 38 km/h (20 – 24 mph)  
4 → 3 14 – 20 km/h (9 – 12 mph)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 50 – 58 km/h (31 – 36 mph)  
2 → 1 42 – 48 km/h (26 – 30 mph)  
L range  
(Throttle valve fully opened)  
2 → 1 45 – 51 km/h (28 – 32 mph)  
Shift schedule (SNOW mode)  
D range  
(Throttle valve fully opened)  
2 → 3 95 – 103 km/h (59 – 64 mph)  
3 → 4 151 – 164 km/h (94 – 102 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 85 – 93 km/h (53 – 58 mph)  
3 → 4 32 – 38 km/h (20 – 24 mph)  
4 → 3 14 – 20 km/h (9 – 12 mph)  
(Throttle valve fully closed)  
Lock–up point (NORM mode)  
(Throttle valve opening 5%)  
3rd Gear (O/D main switch OFF)  
Lock–up ON 52 – 59 km/h (32 – 37 mph)  
Lock–up OFF 49 – 56 km/h (30 – 35 mph)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 68 km/h (38 – 42 mph)  
O/D gear  
Lock–up point (PWR mode)  
(Throttle valve opening 5%)  
3rd Gear (O/D main switch OFF)  
Lock–up ON 55 – 62 km/h (34 – 39 mph)  
Lock–up OFF 52 – 59 km/h (32 – 37 mph)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 68 km/h (38 – 42 mph)  
O/D gear  
Lock–up point (SNOW mode)  
(Throttle valve opening 5%)  
3rd Gear (O/D main switch OFF)  
Lock–up ON 52 – 59 km/h (32 – 37 mph)  
Lock–up OFF 49 – 56 km/h (30 – 35 mph)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 68 km/h (38 – 42 mph)  
O/D gear  
AVENSIS/CORONA SUP (RM781E)  
SS–22  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(A246E)  
SS0YI–02  
TORQUE SPECIFICATION  
Parttightened  
Drain plug x Transaxle case  
Oil pan set bolt  
N·m  
17  
kgf·cm  
ft·lbf  
175  
55  
13  
5.3  
10  
48in.·lbf  
Oil strainer set bolt  
100  
100  
100  
55  
7
Valve body set bolt  
10  
7
Detentspring  
10  
7
Neutral start switch x Transaxle case  
Neutral start switch lock nut  
Control cable x Control shift lever  
Air cleaner assembly set bolt  
Engine mounting bracket LH  
5.4  
6.9  
12  
48in.·lbf  
61in.·lbf  
9
70  
120  
50  
5.0  
43in.·lbf  
Through bolt :  
Set bolt :  
87  
52  
890  
530  
64  
38  
Starter  
39  
64  
43  
39  
400  
650  
440  
400  
29  
47  
32  
29  
Transaxle x Engine  
Exhaust front pipe x Exhaust manihold  
Center member protector set bolt  
Center member set bolt  
A bolt :  
B bolt :  
73  
35  
740  
360  
54  
26  
Starter connector set bolt  
10  
12  
100  
120  
7
9
Control cable bracket x Transaxle  
Engine rear mounting bracket  
Through bolt :  
Set bolt :  
87  
64  
890  
650  
64  
48  
Torque converter x Drive plate  
Engine x Transaxle  
28  
290  
21  
Lower side :  
A bolt :  
46  
23  
470  
230  
34  
17  
B bolt :  
Ground cable x Transaxle  
18  
35  
185  
360  
13  
26  
Suction hose (RHD) x Center member  
AVENSIS/CORONA SUP (RM781E)  
SS–23  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(U240E)  
AUTOMATIC TRANSAXLE (U240E)  
SS18S–02  
SERVICE DATA  
Linepressure (Wheel locked)  
Engineidling  
2
D range 372 – 412 kPa (3.8 – 4.2 kgf/cm , 54 – 59 psi)  
2
R range 640 – 742 kPa (6.5 – 7.6 kgf/cm , 93 – 107 psi)  
at stall (Throttle valve fully opened)  
2
D range 931 – 1,031 kPa (9.5 – 10.5 kgf/cm , 134 – 149 psi)  
2
R range 1,768 – 1,968 kPa (18.0 – 20.1 kgf/cm , 255 – 286 psi)  
Enginestallrevolution  
Time lag  
D and R range 2,550 ± 150 rpm  
N → D range Less than 1.2 seconds  
N → R range Less than 1.5 seconds  
Engine idle speed  
(A/C OFF)  
N range 700 ± 50 rpm  
Drive plate runout  
Max. 0.20 mm (0.0079 in.)  
Max. 0.30 mm (0.0118 in.)  
More than 13.4 mm (0.528 in.)  
Torque converter runout  
Torqueconverterinstallationdistance  
Differential oil seal drive in depth  
LH side 2.7 ± 0.5 mm (0.106 ± 0.020 in.)  
RH side 0 ± 0.5 mm (0 ± 0.020 in.)  
LHD  
Shift schedule (NORM mode)  
D range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 116 – 128 km/h (72 – 80 mph)  
3 → 2 67 – 74 km/h (42 – 46 mph)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 146 –159 km/h (91 – 99 mph)  
3 → 2 92 – 99 km/h (57 – 62 mph)  
2 → 1 46 – 52 km/h (29 – 32 mph)  
3 → 4 35 – 41 km/h (22 – 25 mph)  
4 → 3 16 – 21 km/h (10 – 13 mph)  
(Kick–down Switch ON)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
3 → 2 99 – 106 km/h (62 – 66 mph)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 1 46 – 52 km/h (29 – 32 mph)  
(Kick–down Switch ON)  
L range  
(Throttle valve fully opened)  
3 → 2 99 – 106 km/h (62 – 66 mph)  
2 → 1 48 – 54 km/h (30 – 34 mph)  
AVENSIS/CORONA SUP (RM781E)  
SS–24  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(U240E)  
Shift schedule (PWR mode)  
D range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 81 – 88 km/h (50 – 55 mph)  
2 – 1 46 – 52 km/h (29 – 32 mph)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 146 –159 km/h (91 – 99 mph)  
3 → 2 92 – 99 km/h (57 – 62 mph)  
2 → 1 46 – 52 km/h (29 – 32 mph)  
3 → 4 35 – 41 km/h (22 – 25 mph)  
4 → 3 17 – 23 km/h (11 – 14 mph)  
(Kick–down Switch ON)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
3 → 2 99 – 106 km/h (62 – 66 mph)  
2 → 1 46 – 52 km/h (29 – 32 mph)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 1 46 – 52 km/h (29 – 32 mph)  
(Kick–down Switch ON)  
L range  
(Throttle valve fully opened)  
3 → 2 99 – 106 km/h (62 – 66 mph)  
2 → 1 48 – 54 km/h (30 – 34 mph)  
Shift schedule (SNOW mode)  
D range  
(Throttle valve fully opened)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 116 – 128 km/h (72 – 80 mph)  
3 → 2 67 – 74 km/h (42 – 46 mph)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 146 –159 km/h (91 – 99 mph)  
3 → 2 92 – 99 km/h (57 – 62 mph)  
3 → 4 35 – 41 km/h (22 – 25 mph)  
4 → 3 16 – 21 km/h (10 – 13 mph)  
(Kick–down Switch ON)  
(Throttle valve fully closed)  
Lock–up point (NORM mode)  
O/D gear  
(Throttle valve opening 5%)  
Lock–up ON 58 – 64 km/h (36 – 40 mph)  
Lock–up OFF 54 – 60 km/h (34 – 37 mph)  
Lock–up point (PWR mode)  
O/D gear  
(Throttle valve opening 5%)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 67 km/h (38 – 42 mph)  
AVENSIS/CORONA SUP (RM781E)  
SS–25  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(U240E)  
RHD  
Shift schedule (NORM mode)  
D range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 92 – 99 km/h (57 – 62 mph)  
2 → 1 46 – 52 km/h (29 – 32 mph)  
3 → 4 35 – 41 km/h (22 – 25 mph)  
4 → 3 16 – 21 km/h (10 – 13 mph)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
3 → 2 99 – 10 km/h (62 – 66 mph)  
L range  
(Throttle valve fully opened)  
3 → 2 99 – 107 km/h (62 – 66 mph)  
2 → 1 48 – 54 km/h (30 – 34 mph)  
Shift schedule (PWR mode)  
D range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 92 – 99 km/h (57 – 62 mph)  
2 → 1 46 – 52 km/h (29 – 32 mph)  
3 → 4 35 – 41 km/h (22 – 25 mph)  
4 → 3 17 – 23 km/h (11 – 14 mph)  
(Throttle valve fully closed)  
2 range  
(Throttle valve fully opened)  
1 → 2 53 – 60 km/h (33 – 37 mph)  
3 → 2 99 – 107 km/h (62 – 66 mph)  
L range  
(Throttle valve fully opened)  
3 → 2 99 – 107 km/h (62 – 66 mph)  
2 → 1 48 – 54 km/h (30 – 34 mph)  
Shift schedule (SNOW mode)  
D range  
(Throttle valve fully opened)  
2 → 3 99 – 107 km/h (62 – 66 mph)  
3 → 4 154 – 166 km/h (96 – 103 mph)  
4 → 3 146 – 159 km/h (91 – 99 mph)  
3 → 2 92 – 99 km/h (57 – 62 mph)  
3 → 4 35 – 41 km/h (22 – 25 mph)  
4 → 3 16 – 21 km/h (10 – 13 mph)  
(Throttle valve fully closed)  
Lock–up point (NORM mode)  
O/D gear  
(Throttle valve opening 5%)  
Lock–up ON 58 – 64 km/h (36 – 40 mph)  
Lock–up OFF 54 – 60 km/h (34 – 37 mph)  
Lock–up point (PWR mode)  
O/D gear  
(Throttle valve opening 5%)  
Lock–up ON 64 – 71 km/h (40 – 44 mph)  
Lock–up OFF 61 – 67 km/h (38 – 42 mph)  
AVENSIS/CORONA SUP (RM781E)  
SS–26  
SERVICE SPECIFICATIONS  
–
AUTOMATIC TRANSAXLE(U240E)  
SS0YI–03  
TORQUE SPECIFICATION  
Parttightened  
Input turbine speed sensor x Transaxle case  
Counter gear speed sensor x Transaxle case  
ATF Temperature sensor x Valve body  
Oil strainer x Valve body  
N·m  
11.3  
11.3  
6.6  
kgf·cm  
ft·lbf  
115  
115  
67  
8
8
58in.·lbf  
8
10.8  
7.8  
110  
80  
Oil pan x Transaxle case  
69in.·lbf  
36  
Drainplug  
49  
500  
Neutral start switch x Transaxle  
Bolt:  
5.4  
6.9  
55  
70  
48in.·lbf  
61in.·lbf  
Nut:  
Shaft lever x Body  
12  
13  
120  
130  
9
9
Shift control cable x Control shaft lever  
Solenoid valve x Valve body  
(See page AX–8)  
Bolt A:  
Bolt B:  
6.6  
67  
58in.·lbf  
8
10.8  
110  
Valve body x Transaxle case  
Air cleaner assembly set bolt  
Engine mounting bracket LH  
10.8  
5.0  
110  
50  
8
43in.·lbf  
Through bolt :  
Set bolt :  
87  
52  
890  
530  
64  
38  
Starter  
39  
64  
62  
39  
400  
650  
630  
400  
29  
47  
46  
29  
Transaxle x Engine  
Upper side :  
Exhaust front pipe x Exhaust manihold  
Center member protector set bolt  
Center member set bolt  
A bolt :  
B bolt :  
73  
35  
740  
360  
54  
26  
Starter connector set bolt  
10  
12  
100  
120  
7
9
Control cable bracket x Transaxle  
Engine rear mounting bracket  
Through bolt :  
Set bolt :  
87  
64  
890  
650  
64  
48  
Torque converter x Drive plate  
Engine x Transaxle  
41  
46  
420  
470  
30  
34  
Lower side :  
Solenoid valve x Valve body  
A bolt :  
B bolt :  
6.6  
11  
67  
58in.·lbf  
8
110  
Ground cable x Transaxle  
18  
35  
185  
360  
13  
26  
Suction hose (RHD) x Center member  
AVENSIS/CORONA SUP (RM781E)  
SS–27  
SERVICE SPECIFICATIONS  
–
SUSPENSIONAND AXLE  
SUSPENSION AND AXLE  
SS0IY–03  
SERVICE DATA  
Drive shaft standard length  
1ZZ–FEengine(M/T)  
1ZZ–FE engine (A/T)  
3ZZ–FEengine  
RH 943.60± 1.0 mm (37.15 ± 0.039 in.)  
LH 657.90± 0.8 mm (25.90 ± 0.032 in.)  
RH 943.60 ± 1.0 mm (37.15 ± 0.039 in.)  
LH 653.20± 0.8 mm (25.72 ± 0..032 in.)  
Front drive shaft  
RH 944.70 ± 0.8 mm (37.19 ± 0.032 in.)  
LH 655.70± 0.8 mm (25.82 ± 0.032 in.)  
1AZ–FSEengine  
RH 922.65 ± 1.0 mm (36.32 ± 0.039 in.)  
LH 650.85± 0.7 mm (25.62 ± 0.028 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–28  
SERVICE SPECIFICATIONS  
–
SUSPENSIONAND AXLE  
SS0IZ–03  
TORQUE SPECIFICATION  
Parttightened  
N·m  
kgf·cm  
ft·lbf  
FRONT:  
Steering knuckle x Shock absorber  
Suspension support x Body  
255  
80  
2,600  
820  
475  
82  
188  
59  
Suspension support x Piston rod  
ABS speed sensor set bolt  
47  
34  
8.0  
5.5  
29  
71in.·lbf  
48in.·lbf  
22  
ABS speed sensor wire harness clamp x Shock absorber  
Flexible hose x Shock absorber bracket  
55  
300  
AVENSIS/CORONA SUP (RM781E)  
SS–29  
SERVICE SPECIFICATIONS  
–
BRAKE  
BRAKE  
SS0FS–06  
SERVICE DATA  
Brake pedal height (from asphalt sheet)  
LHD 147.0 – 157.0 mm (5.787 – 6.181 in.)  
RHD 149.5 – 159.5 mm (5.886 – 6.280 in.)  
Brake pedal freeplay  
1 – 6 mm (0.04 – 0.24 in.)  
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf)  
LHD Gasoline engine (w/o ABS) More than 70 mm (2.76 in.)  
LHD Others More than 55 mm (2.17 in.)  
RHD Gasoline engine (w/o ABS) More than 90 mm (3.54 in.)  
RHD Others More than 75 mm (2.95 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–30  
SERVICE SPECIFICATIONS  
–
STEERING  
STEERING  
SS0IF–03  
SERVICE DATA  
POWER STEERING FLUID  
Oil level rise  
Maximum 5 mm (0.20 in.)  
1ZZ–FE, 3ZZ–FE Engines:  
2
Oil pressure at idle speed with valve closed  
1AZ–FSE Engine:  
Minimum 8,300 kPa (85 kgf/cm , 1,209 psi)  
2
Oil pressure at idle speed with valve closed  
POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE)  
Vane pump rotating torque  
Minimum 8,800 kPa (90 kgf/cm , 1,280 psi)  
0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less  
Vane pump shaft and front housing bushing oil clearance  
STD 0.021 – 0.043 mm (0.0008 – 0.0017 in.)  
Maximum 0.07 mm (0.0028 in.)  
Vane plate height  
Minimum 7.6 mm (0.299 in.)  
Minimum 1.405 mm (0.0553 in.)  
Minimum 11.993 mm (0.4722 in.)  
Maximum 0.03 mm (0.0012 in.)  
Vane plate thickness  
Vane plate length  
Vane plate and vane pump rotor groove clearance  
Vane plate length  
pump rotor and cam ring mark  
0
1
2
3
4
12.001 – 12.003 mm (0.47248 – 0.47256 in.)  
11.999 – 12.001 mm (0.47240 – 0.47248 in.)  
11.997 – 11.999 mm (0.47232 – 0.47240 in.)  
11.995 – 11.997 mm (0.47224 – 0.47232 in.)  
11.993 – 11.995 mm (0.47216 – 0.47224 in.)  
Spring free length  
Minimum 35.8 mm (1.409 in.)  
POWER STEERING VANE PUMP (1AZ–FSE)  
Vane pump rotating torque  
0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less  
Vane pump shaft and front housing bushing oil clearance  
STD 0.021 – 0.043 mm (0.0008 – 0.0017 in.)  
Maximum 0.07 mm (0.0028 in.)  
Vane plate height  
Minimum 7.6 mm (0.299 in.)  
Minimum 1.405 mm (0.0553 in.)  
Minimum 11.993 mm (0.4722 in.)  
Maximum 0.03 mm (0.0012 in.)  
Vane plate thickness  
Vane plate length  
Vane plate and vane pump rotor groove clearance  
Vane plate length  
pump rotor and cam ring mark  
0
1
2
3
4
12.001 – 12.003 mm (0.47248 – 0.47256 in.)  
11.999 – 12.001 mm (0.47240 – 0.47248 in.)  
11.997 – 11.999 mm (0.47232 – 0.47240 in.)  
11.995 – 11.997 mm (0.47224 – 0.47232 in.)  
11.993 – 11.995 mm (0.47216 – 0.47224 in.)  
Spring free length  
Minimum 35.8 mm (1.409 in.)  
*: For use with belt tension gauge  
AVENSIS/CORONA SUP (RM781E)  
SS–31  
SERVICE SPECIFICATIONS  
–
STEERING  
SS0IG–03  
TORQUE SPECIFICATION  
Parttightened  
N·m  
kgf·cm  
ft·lbf  
TILT STEERING COLUMN  
Steering column assembly set bolt and nut  
Control valve shaft x Yoke  
25.5  
35  
260  
360  
510  
90  
19  
26  
37  
Steering wheel set nut  
50  
Steering wheel pad set screw (Torx screw)  
POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE)  
Rear housing set bolt  
8.8  
78in.·lbf  
22  
69  
220  
700  
16  
51  
Pressure port union x Front housing  
Suction port union set bolt  
12  
120  
9
Oil pressure switch  
21  
210  
15  
PS vane pump assembly set nut  
Pressure feed tube x PS vane pump assembly  
Pressure feed tube x Rear bracket  
POWER STEERING VANE PUMP (1AZ–FSE)  
Rear housing set bolt  
37  
370  
27  
37(44)  
7.8  
375(450)  
80  
27(33)  
69in.·lbf  
22  
69  
12  
21  
50  
52  
220  
700  
120  
210  
510  
530  
16  
51  
9
Pressure port union x Front housing  
Suction port union set bolt  
Oil pressure switch  
15  
37  
38  
PS vane pump assembly set bolt  
Pressure feed tube x PS vane pump assembly  
( ): For use without SST  
AVENSIS/CORONA SUP (RM781E)  
SS–32  
SERVICE SPECIFICATIONS  
–
BODY  
BODY  
SS0BN–02  
TORQUE SPECIFICATION  
Parttightened  
N·m  
20  
kgf·cm  
205  
ft·lbf  
15  
FRONT BUMPER  
Bumper reinforcement x Body  
AVENSIS/CORONA SUP (RM781E)  
SS–33  
SERVICE SPECIFICATIONS  
–
AIR CONDITIONING  
AIR CONDITIONING  
SS038–06  
SERVICE DATA  
Refrigerantvolume  
460 ± 20 g (16.23 ±0.71 oz.)  
AVENSIS/CORONA SUP (RM781E)  
SS–34  
SERVICE SPECIFICATIONS  
–
AIR CONDITIONING  
SS050–07  
TORQUE SPECIFICATION  
Parttightened  
Compressor x Compressor bracket  
Compressor x Discharge hose  
Compressor x Suction hose  
N·m  
25  
kgf·cm  
250  
100  
100  
55  
ft·lbf  
18  
7
10  
10  
7
Condenser x Liquid tube  
5.5  
5.5  
48in.·lbf  
48in.·lbf  
Condenser x Discharge hose  
55  
AVENSIS/CORONA SUP (RM781E)  

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