suspension TOYOTA AVENSIS 2003 Service Owner's Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.77 MB
Page 184 of 2234
031H2±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±15
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedNmkgf cmft lbf
Camshaft bearing cap No. 3 x Cylinder head sub±assy1313310
Camshaft bearing cap No. 1 x Cylinder head sub±assy2323517
Camshaft timing gear or sprocket x Camshaft No. 25455140
Chain tensioner assy No. 1 x Timing chain or belt cover sub±assy9.09280 in. lbf
V±ribbed belt tensioner assy x Cylinder block sub±assy6970451
V±ribbed belt tensioner assy x Cylinder head sub±assy2929621
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting bracket5253038
Cylinder head cover sub±assy x Cylinder head sub±assy A
B11
9.011 2 928
80 in. lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Ignition coil assy x Cylinder head cover sub±assy9.09280 in.lbf
Engine wire x Cylinder head cover sub±assy9.09280 in.lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.lbf
Engine hanger x Cylinder head sub±assy3838728
Radio setting condenser x Cylinder head sub±assy101027
Engine coolant temperature sensor x Cylinder head sub±assy2020415
Exhaust manifold x Cylinder head sub±assy3737727
Exhaust manifold heat insulator No. 1 x Exhaust manifold Bolt
Nut18
12184
12213 9
Manifold stay No. 2 x Exhaust manifold4950036
Manifold stay No. 2 x Cylinder block sub±assy4950036
Manifold stay x Exhaust manifold A4950036
Manifold stay x Cylinder block sub±assyB3737727
Transverse engine engine mounting bracket x Timing chain or belt cover
sub±assy4747935
V±ribbed idler assy No.1 x Cylinder block sub±assy39.240029
Knock sensor x Cylinder block sub±assy2020415
Crankshaft position sensor x Timing chain or belt cover9.09280 in.lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.lbf
Water inlet x Cylinder block sub±assy1111 28
Water by±pass pipe No. 1 x Cylinder block sub±assy9.09280 in.lbf
Water by±pass pipe No. 1 x Cylinder head sub±assy9.09280 in.lbf
Oil level gage guide x Water by±pass pipe No. 11313310
Intake manifold x Cylinder head sub±assy3030622
Flywheel sub±assy x Crankshaft 1st
2nd49
Turn 90500
Turn 9036
Turn 90
Drive plate & ring gear sub±assy x Crankshaft8889765
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front5253038
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Transverse engine engine mounting bracket LH x Transverse engine engine
mounting insulator LH8081659
Transverse engine engine mounting bracket RH x Transverse engine engine
mounting insulator RH5253038
Front suspension crossmember sub±assy x Body A
B45
133459
1,35633
98
Front suspension member brace x Body Bolt A
Bolt B133 801,356 81698
59
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Page 185 of 2234
03±16
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Floor panel brace front x Body3030622
Battery carrier x Body12.81319
Battery x Body5.05144 in. lbf
Air cleaner case x Body5.05144 in.lbf
Air cleaner case x Transverse engine engine mounting bracket LH5.05144 in.lbf
Radiator support upper x Body1919414
Front wheel RH & LH x Front axle hub sub±assy RH & LH1031,05076
Camshaft timing gear assy x Camshaft5455140
Chain tensioner slipper x Cylinder block sub±assy1919414
Timing chain or belt cover sub±assy x Cylinder head sub±assy1313310
Timing chain or belt cover sub±assy x Cylinder block sub±assy M6
M813
19133
19410
14
Crankshaft pulley x Crankshaft1381,407102
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90500
Turn 9036
Turn 90
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in. lbf
Chain vibration damper No. 1 x Cylinder head sub±assy9.09280 in.lbf
Chain vibration damper No. 1 x Cylinder block sub±assy9.09280 in.lbf
1AZ±FE:
Part TightenedNmkgf cmft lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in. lbf
Drive shaft bearing bracket x Cylinder block5455140
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.lbf
Water inlet x Cylinder block9.09280 in.lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Intake manifold x Cylinder head3030622
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133 801,356 81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356 81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
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Page 186 of 2234
±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedftlbf
kgfcm
Nm
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B
52
113530
1,15238
83
Clutch release cylinder x manual transaxleBolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.lbf
44 in.lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body w/o Air conditioning
RHD (w/ Air conditioning) steering position type
9.0
9.092
9280 in.lbf
80 in.lbf
Cooler bracket x BodyLHD (w/ Air conditioning) steering position type9.09280 in.lbf
Oil reservoir bracket No. 1 x Body8.08271 in.lbf
Return tube sub±assy x Frame8.08271 in.lbf
Radiator reserve tank x sub±assy x body5.05144 in.lbf
Compressor and magnetic clutch x Cylinder blockw/ Air conditioning2525518
Radiator relay block x Frame5.05144 in.lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.lbf
Air cleaner assy x Body5.05144 in.lbf
Cylinder head x Cylinder block1st
2nd79
Turn 90806
Turn 9058
Turn 90
Camshaft timing control valve assy x Cylinder head9.09280 in.lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.lbf
Timing chain guide x Cylinder block9.09280 in.lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±139)Bolt A Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in. lbf
15
32
80 in. lbf
Oil pan x Stiffening crankcase assy9.09280 in.lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1AZ±FSE:
Part TightenedN mkgf cmft lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
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Page 187 of 2234
03±18
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in. lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.lbf
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.lbf
Water inlet x Cylinder block9.09280 in.lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133 801,356 81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356 81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulator A B
52
11 3530
1,15238
83
Clutch release cylinder x manual transaxle Bolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in. lbf
44 in. lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.lbf
Cooler bracket x Body LHD steering position type9.09280 in.lbf
Oil reservoir bracket No. 1 x Body8.08271 in.lbf
Return tube sub±assy x Frame8.08271 in.lbf
Radiator reserve tank x sub±assy x body5.05144 in.lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.lbf
Air cleaner assy x Body5.05144 in.lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90806
Turn 9058
Turn 90
Camshaft timing control valve assy x Cylinder head9.09280 in. lbf
Camshaft timing gear assy x Camshaft5455140
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Page 189 of 2234
03±20
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
kgf cm
N m
Injection pipe, Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe x Injector Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe clamp x Intake manifold5.05144 in. lbf
Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe x injection pump Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Nozzle leakage pipe No.2 x Cylinder head Check valve
Bolt21
8.8214 9015
78 in. lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2121415
Water inlet x Cylinder block8.89078 in.lbf
Water outlet sub±assy x Cylinder head2121415
Exhaust manifold x Cylinder head4747935
EGR pipe sub±assy x Cylinder head Bolt
Nut37
25375
25027
18
Oil filter bracket x Oil pan sub±assy3434725
V±ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub±assy x V±ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in. lbf
Flywheel x Crankshaft7172052
Engine mounting member sub±assy center x Body4545933
Front suspension crossmember sub±assy x Rear engine mounting bracket8788764
Front suspension crossmember sub±assy x Front engine mounting bracket\
5253038
Front suspension crossmember sub±assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub±assy\
1331,35698
Front suspension member brace x Body8081659
Return tube sub±assy x Body8.08271 in.lbf
Engine mounting insulator RH x Body5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Injector driver x Engine mounting insulator RH5.05144 in.lbf
Engine wire x Body8.48574 in.lbf
Air tube No.2 x Manual transaxle2525518
Relay box x Radiator assy5.35446 in.lbf
Fuel filter assy x Fuel filter support1817813
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Page 194 of 2234
0313B±05
03±34
±
SERVICE SPECIFICATIONS FRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
SERVICE DATA
Vehicle height
(Normal package) Front: A *1 ± B *2
Rear: D *4 ± C *3
(Rough road package) Front: A *1
± B *2
Rear: D *4 ± C *3
92 mm (3.62 in.)
61 mm (2.40 in.)
72 mm (2.83 in.)
41 mm (1.61 in.)
Toe±in (total)
Rack end length difference006' 12' (0.1 0.2 ), 1 2 mm (0.04 0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
[Electric motor power steering]
(Normal package) Inside wheel Outside wheel: Reference
(Rough road package) Inside wheel Outside wheel: Reference
\b\f
17' 2
\b\f\f
32
52' \b\f
\b\f
42' 2
\b\f
33
16' \b\b
Front wheel align-
ment
Wheel angle
[Oil pressure power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel Outside wheel: Reference
\b
47' 2
\b \f
31
15' \b
\b
09' 2
\b
31
38' \b
\b
Camber
Normal package
Rough road package
Right±left error
±0
34' 45' (±0.57
0.75
)
±0
19' 45' (±0.32
0.75
)
45' (0.75
) or less
Caster
Normal package
Rough road package
Right±left error
54' 45' (2.90
0.75
)
40' 45' (2.67
0.75
)
45' (0.75
) or less
Steering axis inclination
Normal package
Rough road package
Right±left error
12
27' 45' (12.45
0.75
)
11
56' 45' (11.93
0.75
)
45' (0.75
) or less
Front suspensionLower ball joint turning torque0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
*1: Ground clearance of front wheel center
*2: Ground clearance of lower suspension arm front bolt center
*3: Ground clearance of toe control arm inner bolt center
*4: Ground clearance of rear wheel center
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Page 195 of 2234
0313A±05
±
SERVICE SPECIFICATIONS FRONT SUSPENSION
03±35
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
Tie rod end lock nut7475555
Steering knuckle x Shock absorber2202,240162
Hub nut1031,05076
Suspension support x Piston rod4747935
Suspension support x Body3939829
Suspension crossmember sub±assy x Body1331,36098
Suspension crossmember sub±assy x Engine mounting insulator8081659
Suspension crossmember sub±assy x Center member9697971
Suspension member brace x Body Bolt A:
Bolt B:80
133816
1,36059
98
Speed sensor wire harness bracket set bolt1919214
Stabilizer bracket No.1 x Suspension crossmember (w/o HID)1919414
Stabilizer bracket No.1 x Suspension crossmember (w/ HID) Bolt A: Bolt B:5.41955
19448
14
Stabilizer bar link set nut7475555
Lower suspension arm x Lower ball joint8990866
Lower ball joint x Steering knuckle1031,05076
Lower suspension arm x Suspension crossmember1371,400101
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Page 206 of 2234
031HC±01
±
SERVICE SPECIFICATIONS LIGHTING
03±65
AVENSIS REPAIR MANUAL (RM1018E)
LIGHTING
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
Height control sensor sub±assy Fr RH x Body7.98170 in. lbf
Height control sensor sub±assy Fr RH x Stabilizer bar rear5.85951 in.lbf
Height control sensor sub±assy Rr RH x Suspension menber7.98170 in.lbf
Height control sensor sub±assy Rr RH x Upper control arm assy5.85951 in.lbf
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Page 216 of 2234
030G7±04
03±60
±
SERVICE SPECIFICATIONS POWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedN mkgf cmft lbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in. lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356 81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in. lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)
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Page 217 of 2234
031HF±01
03±36
±
SERVICE SPECIFICATIONS REAR SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION
SERVICE DATA
Toe±in (total) Normal package:
Rough road package:
0 18' 12' (0.3 0.2 , 3.0 2.0 mm, 0.12 0.08 in.)
0 18' 12' (0.3 0.2 , 3.0 2.0 mm, 0.12 0.08 in.)
Rear wheel align-
mentCamber
Normal package:
Rough road package:
Right±left error
±0 ' 30' (±0.9 0.5 )
±0 30' 30' (±0.5 0.5 )
30' (0.5 ) or less
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