TOYOTA AVENSIS 2002 Repair Manual

±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH(MTM)26±23
AVENSIS REPAIR MANUAL (RM1018E)
12.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)

2600K±06
±
FRONT SUSPENSION FRONT SUSPENSION SYSTEM
26±1
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
4. Tire (Worn or improperly inflated)
5. Wheel alignment (Incorrect)
6. Steering linkage (Loose or worn)
7. Hub bearing (Worn)
8. Steering gear (Out of adjustment or broken)
9. Suspension parts (Worn)28±1
26±6
±
30±2
51±28
51±36
±
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)±
26±10
26±10
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28±1
26±26
26±10
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loose or worn)
8. Steering gear (Out of adjustment or broken)28±1
28±1
26±10 26±6
26±24
30±2 ±
51±28
51±36
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28±1
26±6
26±10 ±

2600L±02
F44617
Front:AB
F44618
Rear:
C D
SA3213
A
D B
Front
C
F44619
26±6
±
FRONT SUSPENSION FRONT WHEEL ALIGNMENT
AVENSIS REPAIR MANUAL (RM1018E)
FRONT WHEEL ALIGNMENT
ADJUSTMENT
1.INSPECT TIRE (See page 28±1) 2. MEASURE VEHICLE HEIGHT
Vehicle height:
(Normal package)
FrontA ± B: 92 mm (3.62 in.)
RearD ± C: 61 mm (2.40 in.)
(Rough road package)
FrontA ± B: 72 mm (2.83 in.)
RearD ± C: 41 mm (1.61 in.)
Measuring points:
A: Ground clearance of front wheel center
B: Ground clearance of lower suspension arm front bolt
center
C: Ground clearance of toe control arm inner bolt center
D: Ground clearance of rear wheel center
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specified value.
If the vehicle height is not the specified value, adjust it by push-
ing down or lifting the body.
3. INSPECT TOE±IN
Toe±in:
Toe±in(total)A + B: 0
06'  12' (0.1
 0.2
)
C ± D: 1  2 mm (0.04  0.08 in.)
If the toe±in is not within the specified value, adjust it at the rack
ends.
4. ADJUST TOE±IN
(a) Remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to
adjust the toe±in.
HINT:
Adjust the toe±in to the center of the specified value as much
as possible.
(d) Make sure that the lengths of the right and left rack ends are the same.
(e) Torque the tie rod end lock nuts.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
(f) Place the boots on the seats and install the clips.
HINT:
Make sure that the boots are not twisted.

SA0028
AB
FrontA B
A: Inside
B: Outside
Z03382
Alignment
TesterGauge
± FRONT SUSPENSIONFRONT WHEEL ALIGNMENT
26±7
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully and measure the turning
angle.
Wheel turning angle:
(Normal package)
Inside wheel
17'  2 

  

47'  2 

  
Outside wheel: Reference3252'  

315'  

(Rough road package)
Inside wheel
42'  2 
  
09'  2  
  
Outside wheel: Reference3316'  
3138'   
*1: Electric motor power steering models
*2: Oil pressure power steering models
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Install the camber±caster±kingpin gauge or position the
vehicle on the wheel alignment tester.
(b) Inspect the camber, caster and steering axis inclination.
Camber, caster and steering axis inclination:
(Normal package)
Camber
Right±left error±034'  45' (±0.57  0.75)
45' (0.75) or less
Caster
Right±left error54'  45' (2.90  0.75)
45' (0.75) or less
Steering axis inclination
Right±left error27'  45' (12.45  0.75)
45' (0.75) or less
(Rough road package)
Camber
Right±left error±019'  45' (±0.32  0.75)
45' (0.75) or less
Caster
Right±left error40'  45' (2.67  0.75)
45' (0.75) or less
Steering axis inclination
Right±left error56'  45' (11.93  0.75)
45' (0.75) or less
If the caster and steering axis inclination are not within the spe-
cified values, after the camber has been correctly adjusted, re-
check the suspension parts for damaged and/or worn out parts.

F13683
26±8
± FRONT SUSPENSIONFRONT WHEEL ALIGNMENT
AVENSIS REPAIR MANUAL (RM1018E)
7. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe±in.
(a) Remove the front wheel.
(b) Remove the 2 bolts and nuts on the lower side of the
shock absorber.
If reusing the bolts and/or nuts, coat the threads of nuts with en-
gine oil.
(c) Clean the installation surfaces of the shock absorber and
the steering knuckle.
(d) Temporarily install the 2 bolts and nuts.

F44962
+
±
F13685
1
2
F12938
Bolt
Adjusting
ValueSet BoltAdjusting Bolt90105±17008 90105±17009
90105±17010 90105±17011
121212121 Dot
2 Dots3 Dots
±130' ± ±115'
±115' ± ±100'
±100' ± ±45'
±45' ± ±30'
±30' ± ±15'
0' ± 15'
15' ± 30'
30' ± 45'
45' ± 1

100' ± 115' ±15' ± 0'
115' ± 130'
± FRONT SUSPENSIONFRONT WHEEL ALIGNMENT
26±9
AVENSIS REPAIR MANUAL (RM1018E)
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
(f) Tighten the nuts.
Torque: 220 N
m (2,240 kgf
cm, 162 ft
lbf)
(g) Install the front wheel.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
HINT:

Adjust the camber to the center of the specified value as
much as possible.

Adjusting value for the set bolts is 6' ± 30' (0.1 ± 0.5).
If the camber is not within the specified value, using the follow-
ing table, estimate how much additional camber adjustment will
be required, and select the camber adjusting bolt.
NOTICE:
Tighten the adjusting bolt with a washer and a new nut.
(i) Perform the procedure mentioned above again. At step
(b), replace 1 or 2 selected bolts.
HINT:
When replacing the 2 bolts, replace 1 bolt for each time.

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

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)