TOYOTA AVENSIS 2002 Repair Manual

F44615
Rack & Pinion Power
Steering Gear Assy
49 (500, 36)
Tie Rod End Sub±assy LH
Front Stabilizer Link Assy RH
Transverse Engine
Engine Mounting Insulator
Front Stabilizer Link Assy LH
Front Suspension
Crossmember Sub±assy
Front Suspension
Member Body Mounting
Stopper FR
133 (1,360, 98)
137 (1,400, 101)
Body Mounting Stopper Rear
52 (530, 38)
80 (816, 59)
74 (755, 55)
Front Suspension
Member Brace
Rear LH
80 (816, 59)
133 (1,360, 98)
Cotter Pin
49 (500, 36)
89 (908, 66)
Front Suspension Arm
Sub±assy Lower No.1 LH
80 (816, 59)
133 (1,360, 98)
80 (816, 59)
Front Suspension
Member Brace
Rear RH
133 (1,360, 98)
137 (1,400, 101)
N
m (kgf
cm, ft
lbf) : Specified torque

Nblt

Non±reusable part

Engine Mounting Member
Sub±assy Center
96 (979, 71)
± FRONT SUSPENSIONFRONT SUSPENSION
26±3
AVENSIS REPAIR MANUAL (RM1018E)

F44616
89 (908, 66)
102 (1,040, 75)
220 (2,240, 162)
8 (82, 71 in.
lbf)
49 (500, 36)
103 (1,050, 76)
216 (2,200, 159)
Front Shock Absorber with Coil Spring
Front Drive Shaft Assy LHSpeed Sensor Front LH
Cotter Pin
Front Disc
Tie Rod End
Sub±assy LH
Cotter Pin
Front Disc Brake
Caliper Assy LH
Front Suspension Arm
Sub±assy Lower No.1 LH
Lower Ball Joint Assy Front LH
Front Axle Assy LHFront Axle Hub LH Nut
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part



26±4
± FRONT SUSPENSIONFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)

F45154
Rack & Pinion
Power Steering Gear Assy
Tie Rod End
Sub±assy LH
Front Stabilizer Link
Assy LH
Stabilizer Bar Front Front Stabilizer Link
Assy RH
Front Suspension Arm
Sub±assy Lower No.1 RH
Front Suspension
Member Brace
Rear RHFront Stabilizer
Bar Bush No.1
Front Suspension
Crossmember Sub±assy
Front Suspension
Arm Sub±assy
Lower No.1 LH
Body Mounting
Stopper Rear
Front Suspension
Member Body
Mounting Stopper FR
Front Suspension
Member Brace Rear LH
Cotter Pin

89 (908, 66)
133 (1,360, 98)
49 (500, 36)
74 (755, 55)
80 (816, 59)
133 (1,360, 98)
74 (755, 55)
49 (500, 36)
80 (816, 59)
19 (194, 14)
19 (194, 14)
133 (1,360, 98)
80 (816, 59)
133 (1,360, 98)
80 (816, 59)
19 (194, 14)
49 (500, 36)
74 (755, 55)
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

5.4 (55, 48 in.
lbf)w/ HID:
HID Height
Control Sensor
Front Stabilizer
Bracket No.1 RH
Front Stabilizer
Bracket No.1 LH
96 (979, 71)
80 (816, 59)
52 (530, 38)
± FRONT SUSPENSIONFRONT SUSPENSION
26±5
AVENSIS REPAIR MANUAL (RM1018E)

260DQ±01
F13686
C80293
26±16±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)
REPLACEMENT
HINT:

COMPONENTS: See page 26±2

Replace the RH side (Engine: 1AZ) by the same procedures as the LH (A\
TM) side.

Replace the RH side (Engine: 1ZZ) by the same procedures as the LH (M\
TM) side.
1. REMOVE FRONT WHEELS
2. SEPARATE FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the stabilizer bar link fromthe shock absorber.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Separate the RH side by the same procedures as the LH side.
4.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
5. SEPARATE TIE ROD END SUB±ASSY RH SST 09628±62011
HINT:
Separate the RH side by the same procedures as the LH side.
6. SEPARATE FRONT SUSPENSION ARM SUB±ASSYLOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and separate the front sus- pension arm sub±assy lower No.1 from the lower ball
joint.
7. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Separate the RH side by the same procedures as the LH side.
8. SEPARATE RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
9. SUSPEND ENGINE ASSY
(a)U341E: See page 40±11
(b)U241E: See page 40±25

C95317
C86742
C87504
C95318
± FRONT SUSPENSIONFRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)26±17
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE FRONT SUSPENSION MEMBER BRACE
REAR LH
(a) Support the front suspension crossmember sub±assy
with a transmission jack.
(b) Remove the 4 bolts and front suspension member brace
rear LH.
(c) Remove the front suspension member body mounting
stopper rear from the front suspension member brace
rear LH.
11. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Remove the RH side by the same procedures as the LH side.
12. SEPARATE FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) w/ HID:
Disconnect the height control sensor (Front) connector.
(b) Remove the 3 bolts and 3 nuts, disconnect the transverse
engine engine mounting insulator and engine mounting
member sub±assy center from the front suspension
crossmember sub±assy.
(c) Remove the 2 nuts and 2 front suspension member body
mounting stoppers front.
(d) Lower the transmission jack, remove the front suspension
crossmember sub±assy.
13. REMOVE FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Remove the 2 bolts, nut and lower suspension arm sub±
assy lower No.1 LH from the front suspension crossmem-
ber sub±assy.

C95318
C87504
C86742
AA
AAB
B
C95317
AA
A
B
26±18
±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH(ATM)
AVENSIS REPAIR MANUAL (RM1018E)
14.TEMPORARILY TIGHTEN FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a)Install the lower suspension arm sub±assy lower No.1
LH, and temporarily tighten the 2 bolts and nut.
15.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY
(a)Support the front suspension crossmember sub±assy with a transmission jack.
(b)Install the 2 front suspension member body mounting stoppers front and 2 nuts.
Torque: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
(c)Connect the transverse engine engine mounting insula- tor and engine mounting member sub±assy center to the
front suspension crossmember sub±assy.
(d)Install the 3 bolts and 3 nuts. Torque:
Bolt A: 52 N
m (530 kgf
cm, 38 ft
lbf)
Bolt B: 96 N
m (979 kgf
cm, 71 ft
lbf)
(e)w/ HID: Connect the height control sensor (Front) connector.
16.INSTALL FRONT SUSPENSION ME MBER BRACE
REAR LH
(a)Install the front suspension member body mounting stop- per rear to the front suspension member brace rear LH.
(b)Install the 4 bolts and front suspension member brace rear LH.
Torque:
Bolt A: 80 N
m (816 kgf
cm, 59 ft
lbf)
Bolt B: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
17.INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
18.CONNECT RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36

C80293
F13686
C80889
±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)26±19
AVENSIS REPAIR MANUAL (RM1018E)
19. CONNECT FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Connect the lower suspension arm to the lower ball joint
with the 2 nuts and bolt.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)
20. CONNECT FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
21.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
22. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side. 23. CONNECT FRONT STABILIZER LINK ASSY LH
(a) Install the stabilizer bar link with the nut.Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
24. CONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
25. STABILIZE SUSPENSION
(a) Install the front wheel and jack down the vehicle. Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b) Bounce the vehicle up and down several times to stabilize the suspension\
.
26. FULLY TIGHTEN FRONT SUSPENSION ARMSUB±ASSY LOWER NO.1 LH
(a) Fully tighten the 2 bolts and nut.
Torque: 137 N
m (1,400 kgf
cm, 101 ft
lbf)

26±20±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
27.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)

260DR±01
F13686
F41742
C80889
±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (MTM)26±21
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (MTM)
REPLACEMENT
HINT:

COMPONENTS: See page 26±2

Replace the RH side (Engine: 1AZ) by the same procedures as the LH (A\
TM) side.

Replace the RH side (Engine: 1ZZ, 3ZZ, 1CD) by the same procedures as \
the LH (MTM) side.
1. REMOVE FRONT WHEELS
2. SEPARATE FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the stabilizer bar link fromthe shock absorber.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Separate the RH side by the same procedures as the LH side. 4. SEPARATE FRONT SUSPENSION ARM SUB±ASSYLOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and separate the lower sus- pension arm from the lower ball joint.
5. REMOVE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a) Remove the 2 bolts, nut and lower suspension arm sub±
assy lower No.1 LH from the front suspension crossmem-
ber sub±assy.

C80889
F41742
F13686
C80889
26±22± FRONT SUSPENSIONFRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
6. TEMPORARILY TIGHTEN FRONT SUSPENSION ARM
SUB±ASSY LOWER NO.1 LH
(a) Install the lower suspension arm, temporary tighten the 2
bolts and nut.
7. CONNECT FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Connect the lower suspension arm to the lower ball joint
with the 2 nuts and bolt.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)
8. CONNECT FRONT STABILIZER LINK ASSY LH
(a) Install the stabilizer bar link with the nut.
Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
9. CONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
10. STABILIZE SUSPENSION
(a) Install the front wheel and jack down the vehicle.
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b) Bounce the vehicle up and down several times to stabilize the suspension.
11. FULLY TIGHTEN FRONT SUSPENSION ARM
SUB±ASSY LOWER NO.1 LH
(a) Fully tighten the 2 bolts and nut.
Torque: 137 N
m (1,400 kgf
cm, 101 ft
lbf)