wheel alignment TOYOTA AVENSIS 2002 Repair Manual

G23168
F08658
SST
G23167
32±62
±
BRAKE SKID CONTROL SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
7. INSTALL SKID CONTROL SENSOR
(a) Clean the contacting surface of the axle hub and that of a new skid control sensor.
NOTICE:
Make sure the sensor rotor is clean.
(b) Place the skid control sensor on the axle hub so that the connector comes into the most downward position under
the on vehicle condition.
(c) Using SST and a press, install the skid control sensor to the axle hub.
NOTICE:

Do not tap the skid control sensor directly with a ham-
mer.

Check that there is no foreign matter on the skid con-
trol sensor detection portion.

Press in the skid control sensor straight and slowly.
SST 09830±36010, 09950±60010 (09951±00650), 09950±70010 (09951±07100)
8.INSTALL REAR AXLE HUB & BEARING ASSY LH (See page 30±31)
9. INSTALL REAR BRAKE DRUM SUB±ASSY
(a) Aligning the matchmarks, install the rear disc.
10. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
11. CONNECT SKID CONTROL SENSOR WIRE
(a) Connect the connector from the skid control sensor.
12. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
13.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
14.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)

4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26

Q01060
D30059
1CD±FTV Engine Type: Others:
Flywheel Side
SST(s)
D26323
SST(s)
Matchmarks 7
1 (Temporally), 4
3
6
2.58
D00205
SST(s)
42±28
± CLUTCHCLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
12. INSPECT CLUTCH RELEASE BEARING ASSY
(a) Turn the release bearing by hand while applying force in
the axial direction.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
Replace the release bearing assy as necessary.
13. INSTALL CLUTCH DISC ASSY
(a) Insert SST(s) in the clutch disc assy, then insert them in
the flywheel sub±assy.
SST 09301±00220
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
14. INSTALL CLUTCH COVER ASSY
(a) Align matchmarks on the clutch cover assy and flywheel
sub±assy.
(b) Following the procedures shown in the illustration, tighten
the 6 bolts, in the order starting from the bolt located near
the knock pin on the top.
Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
HINT:

Following the order in the illustration, tighten the bolts at
a time evenly.

Move SST(s) up and down, right and left lightly, after
checking that the disc is in the center, and then tighten the
bolts.
15. INSPECT AND ADJUST CLUTCH COVER ASSY
(a) Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non±alignment: 0.5 mm (0.020 in.)
If the alignment is not as specified, adjust the diaphragm spring
tip alignment using SST(s).
SST 09333±00013

3005C±02
±
DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT, PROPELLER SHAFT, AXLE
30±1
AVENSIS REPAIR MANUAL (RM1018E)
DRIVE SHAFT, PROPELLER SHAFT, AXLE
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
5. Wheel
6. Front wheel alignment
7. Rear wheel alignment
8. Hub bearing (Worn)
9. Front shock absorber
10.Rear shock absorber28±1
26±6
27±4
30±2
26±10
27±8
Front wheel shimmy
1. Wheel (Imbalance)
2. Hub bearing (Worn)
3. Lower suspension arm ATM:
4. Lower suspension arm MTM:
5. Lower ball joint (Worm)
6. Front shock absorber28±1
30±2
26±16
26±21
26±24
26±10
Noise (Front)
1. Front drive shaft
2. Front shock absorber
3. Hub bearing (Worn)
4. Lower ball joint (Worm)30±6
26±10 30±2
26±24
Noise (Rear)1. Hub bearing (Worn)
2. Rear shock absorber30±2
27±8

C68609
30±28
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
34. INSTALL FRONT AXLE HUB LH NUT
(a) While applying the brakes, install a new axle hub LH nut. Torque: 216 N
m (2,200 kgf
cm, 159 ft
lbf)
(b) Using a chisel and hammer, stake the axle hub LH nut.
35. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
36.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
37. CHECK ABS SPEED SENSOR SIGNAL
(a)ABD WITH EBD SYSTEM (See page 05±699)
(b)ABD WITH EBD & BA & TRC & VSC SYSTEM ( See page 05±756)

±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB±ASSY LH
30±35
AVENSIS REPAIR MANUAL (RM1018E)
34. FULLY TIGHTEN UPPER CONTROL ARM ASSY
(a) Fully tighten the bolt.
Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
NOTICE:
When installing the bolt, hold the nut not to rotate.
35. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH
(a) Fully tighten the nut (ball joint side). Torque: 105 N
m (1,071 kgf
cm, 77 ft
lbf)
(b) Install the clip.
NOTICE:
If the holes for the clip are not aligned, tighten the nut up to 60
further.
(c) Fully tighten the bolt and nut.
Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
NOTICE:
When installing the bolt, hold the nut not to rotate.
36. FULLY TIGHTEN LOWER CONTROL ARM ASSY LH
(a) Fully tighten the nut. Torque: 60 N
m (612 kgf
cm, 44 ft
lbf)
(b) Install the clip.
NOTICE:
If the holes for the clip are not aligned, tighten the nut up to 60
further.
(c) Fully tighten the bolt (member side). Torque: 105 N
m (1,071 kgf
cm, 77 ft
lbf)
NOTICE:
When installing the bolt, hold the nut not to rotate.
37.INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
38.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
39. CHECK ABS SPEED SENSOR SIGNAL
(a)ABD WITH EBD SYSTEM (See page 05±699)
(b)ABD WITH EBD & BA & TRC & VSC SYSTEM ( See page 05±756)

14±134
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
155.INSTALL RADIATOR ASSY (See page 16±24)
156.INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
157.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
158.ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
159.ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
160.ADD ENGINE OIL
161.ADD COOLANT (See page 16±19)
162. ADD POWER STEERING FLUID
163. BLEED POWER STEERING FLUID
164. CHECK FOR ENGINE OIL LEAKS
165.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
166.CHECK FOR FUEL LEAKS (See page 11±15)
167. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
168.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
169.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±101)
170.INSPECT CO/HC (See page 14±101)
171. CHECK ABS SPEED SENSOR SIGNAL

14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)

A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N
m (131 kgf
cm, 9 ft
lbf)
138. INSTALL BATTERY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
145. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL

C80880
F13686
26±14
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
(d) Install the flexible hose and ABS speed sensor wire har- ness bracket with the bolt.
Torque: 19 N
m (192 kgf
cm, 14 ft
lbf)
25. INSTALL 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.
26. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
27.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)