TOYOTA AVENSIS 2005 Service Repair Manual

270E0±01

G26285
w/ Height Control Sensor:
5.8 (59, 51 in.
lbf)
80 (816, 59)
Rear Suspension Member Sub±assy
Rear Shock Absorber
Cushion Washer No.1
Coil Rear Spring
Rear Coil Spring Insulator Upper LH
Rear Spring Bumper No.1 LH
Rear Suspension Support Assy LH
Rear Spring Front Bracket
Sub±assy LH
Rear Shock
Absorber Cushion No.1
Lower Control Arm Assy RH
Rear Shock Absorber
Assy LH
160 (1,632, 118)
110 (1,122, 81)
65 (663, 48)
Rear Suspension
Support Stopper
Rear Suspension Arm
Bracket Assy LH
Rear Suspension
Arm Bush No.1
Camber Adjust Cam Assy
Rear Suspension Arm Assy No.1 LH
74 (755, 55)
105 (1,071, 77)
44 (449, 32)
74 (755, 55)
74 (755, 55)
Parking Brake Cable Assy No.3
5.0 (51, 44 in.
lbf)Rear Axle Carrier Sub±assy LH
Skid Control Sensor Wire
74 (755, 55)
Upper Control Arm Assy
Camber Adjust Cam No.2
Lower Control Arm Assy LH
105 (1,071, 77)
5.0 (51, 44 in.
lbf)
60 (612, 44)
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

56 (571, 41)

56 (571, 41)
Clip
Clip 27±2
± REAR SUSPENSIONREAR SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION
COMPONENTS

G23885
Rear Stabilizer Link Assy RH
Stabilizer Bush Rear
Rear Stabilizer Bar
Bracket No.3
Rear Stabilizer
Link Assy LH Rear Stabilizer Bar Bracket No.3
Stabilizer Bush Rear
Stabilizer Bar Rear
35 (357, 26)
44 (449, 32)
35 (357, 26)
44 (449, 32)
44 (449, 32)
44 (449, 32)
N
m (kgf
cm, ft
lbf) : Specified torque
± REAR SUSPENSIONREAR SUSPENSION
27±3
AVENSIS REPAIR MANUAL (RM1018E)

270E7±01
±
REAR SUSPENSION REAR SUSPENSION SYSTEM
27±1
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the probability
of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loose or worn)
4. Hub bearing (Worn)
5. Suspension parts (Worn)28±1
27±4
±
30±2 ±
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)±
27±8
27±8
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28±1
27±29 27±8
Rear wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Hub bearing (Worn)28±1
28±1
27±8
27±4
30±2
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28±1
27±4
27±8
±

2600P±03
F44620
G21679
26±26
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
STABILIZER BAR FRONT
REPLACEMENT
HINT:
COMPONENTS: See page 26±2
1. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and front stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut,use a hexagon wrench
(6 mm) to hold the stud.
3. REMOVE FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side. 4. INSPECT FRONT STABILIZER LINK ASSY LH
(a) As shown in the illustration, flip the ball joint stud back andforth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate
of 3 ± 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
5.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
6. SEPARATE TIE ROD END SUB±ASSY RH
SST 09628±62011
HINT:
Separate the RH side by the same procedures as the LH side.
7.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
8. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Separate the RH side by the same procedures as the LH side.
9. 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

F45155

F40197
Inner SideRear
Side
±
FRONT SUSPENSION STABILIZER BAR FRONT
26±27
AVENSIS REPAIR MANUAL (RM1018E)
10. SUSPEND ENGINE ASSY
(a)1ZZ, 3ZZ Engine: See page 41±15
(b)1AZ Engine: See page 41±24
(c)1CD Engine: See page 41±33
11.REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
12. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Remove the RH side by the same procedures as the LH side.
13.SEPARATE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
14. REMOVE FRONT STABILIZER BRACKET NO.1 LH
(a) Remove the 2 bolts and the front stabilizer bracket No.1 LH.
15. REMOVE FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID:Remove the 3 bolts, the front stabilizer bracket No.1 RH
and the height control sensor (Front).
(b) w/o HID:
Remove the 2 bolts and the front stabilizer bracket No.1
RH.
16. REMOVE FRONT STABILIZER BAR BUSH NO.1
(a) Remove the 2 bushings from the stabilizer bar.
17. REMOVE STABILIZER BAR FRONT
18. INSTALL STABILIZER BAR FRONT 19. INSTALL FRONT STABILIZER BAR BUSH NO.1
(a) Install the 2 front stabilizer bar bush No.1 to the stabilizerbar front as shown in the illustration.
HINT:
Install the bushing to the outer side of the bushing stopper on
the stabilizer bar.
20. INSTALL FRONT STABILIZER BRACKET NO.1 LH
(a) Install the front stabilizer bracket No.1 LH with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)

F45155
A
B
F44620
26±28
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
21. INSTALL FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID: Install the front stabilizer bracket No.1 RH and the height
control sensor (Front) with the 3 bolts.
Torque:
Bolt A: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
Bolt B: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b) w/o HID: Install the front stabilizer bracket No.1 RH with the 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
22.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
23.INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
24. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
25. INSTALL 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
26.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
27. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
28.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
29. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side.
30. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the 2 nuts.Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
31. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
32. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
33.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
34.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)

260DS±01
G22708
F40228
SST
ZX1712
26±24
±
FRONT SUSPENSION LOWER BALL JOINT ASSY FRONT LH
AVENSIS REPAIR MANUAL (RM1018E)
LOWER BALL JOINT ASSY FRONT LH
REPLACEMENT
HINT:

COMPONENTS: See page 26±2

Replace the RH side by the same procedures as the LH side. 1. INSPECT LOWER BALL JOINT ASSY FRONT LH
(a) Jack up front side of the vehicle.
(b) Check that there is no looseness on the ball joint by shak-ing the lower arm up and down with a force of 294 N (30
kgf, 66 lbf).
2. REMOVE FRONT WHEEL
3.SEPARATE FRONT AXLE HUB LH NUT (See page 30±6) SST 09930±00010
4.DISCONNECT SPEED SENSOR FRONT LH (See page 30±6)
5.SEPARATE FRONT DISC BRAKE CALIPER ASSY LH (See page 30±22)
6. REMOVE FRONT DISC
7.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±22) SST 09628±62011
8.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±22)
9.REMOVE FRONT AXLE ASSY LH (See page 30±22)
10. REMOVE LOWER BALL JOINT ASSY FRONT LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the lower ball joint assy front LH.
11. INSPECT LOWER BALL JOINT ASSY FRONT LH
(a) As shown in the illustration, flip the ball joint stud back andforth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate of 3 ± 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)

±
FRONT SUSPENSION LOWER BALL JOINT ASSY FRONT LH
26±25
AVENSIS REPAIR MANUAL (RM1018E)
12. INSTALL LOWER BALL JOINT ASSY FRONT LH
(a) Install the lower ball joint assy front LH, and torque the nut.
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut further\
up to 60
.
13.INSTALL FRONT AXLE ASSY LH (See page 30±22)
14.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±22)
15.INSTALL TIE ROD END SUB±ASSY LH (See page 30±22)
16. INSTALL FRONT DISC
17.INSTALL FRONT DISC BRAKE CALIPER ASSY LH (See page 30±22)
18.CONNECT SPEED SENSOR FRONT LH (See page 30±6)
19.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
20. INSTALL FRONT WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
21.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
22. CHECK ABS SPEED SENSOR SIGNAL
(a)w/o VSC: See page 05±699
(b)w/ VSC: See page 05±756

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)