TOYOTA AVENSIS 2003 Service Repair Manual

28mm
F44963
F40270
SST
F08624
SST
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
26±11
AVENSIS REPAIR MANUAL (RM1018E)
4. FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower side of
the shock absorber and secure it in a vise.
5. REMOVE FRONT SUSPENSION SUPPORT DUST COVER LH 6. REMOVE FRONT SUPPORT TO FRONT SHOCKABSORBER LH NUT
(a) Using SST, compress the coil spring. SST 09727±30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Remove the front suspension support dust cover from the
suspension support.
(c) Using SST to hold the spring seat, remove the nut. SST 09729±22031
7. REMOVE FRONT SUSPENSION SUPPORT SUB±ASSY LH
8. REMOVE FRONT SUSPENSION SUPPORT LH DUST SEAL
9. REMOVE FRONT COIL SPRING SEAT UPPER LH
10. REMOVE FRONT COIL SPRING INSULATOR UPPER LH
11. REMOVE FRONT COIL SPRING LH
12. REMOVE FRONT SPRING BUMPER LH
13. REMOVE FRONT COIL SPRING INSULATOR LOWER LH
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C80884
F40271
SST
F13692
OutsideOutside
F40272
Outside
26±12
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
14. INSPECT SHOCK ABSORBER ASSY FRONT LH
(a) Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound
during operation.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When disposing of the shock absorber, see DISPOSAL on
page 26±15.
15. INSTALL FRONT COIL SPRING INSULATOR LOWER LH
HINT:
Fit the front coil spring insulator lower into the gap of the shock abso\
rber.
(a) Install the front coil spring insulator lower onto the shock absorber.
16. INSTALL FRONT SPRING BUMPER LH
(a) Install the spring bumper to the piston rod.
17. INSTALL FRONT COIL SPRING LH
(a) Using SST, compress the coil spring.SST 09727±30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the front coil
spring insulator lower LH.
18. INSTALL FRONT COIL SPRING INSULATOR UPPER LH
(a) Install the upper insulator as shown in the illustration.
19. INSTALL FRONT COIL SPRING SEAT UPPER LH
(a) Install the spring seat to the shock absorber with the mark facing to the outside of the vehicle.
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F08624
SSTSST
F40273
MP Grease No. 2
F44622
F13683
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
26±13
AVENSIS REPAIR MANUAL (RM1018E)
20. INSTALL FRONT SUSPENSION SUPPORT LH DUST SEAL
(a) Install a new dust seal.
21. INSTALL FRONT SUSPENSION SUPPORT SUB±ASSY LH
22. I N S TA L L F R O N T S U P P O R T TO F R O N T S H O C KABSORBER LH NUT
(a) Using SST to hold the suspension support, install a new nut.
SST 09729±22031
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
(b) Remove the SST.
SST 09727±30021,09729±22031
23. INSTALL FRONT SUSPENSION SUPPORT DUST COVER LH
(a) Apply MP grease No. 2 into the suspension support.
CAUTION:
Do not touch grease on rubber surface of the suspension
support.
(b) Install the dust cover.
24. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install the shock absorber with the 2 bolts.
(b) Install the 3 nuts on the upper side of shock absorber. Torque: 39 N
m (398 kgf
cm, 29 ft
lbf)
(c) Install the 2 nuts to the lower side of shock absorber. Torque: 220 N
m (2,240 kgf
cm, 162 ft
lbf)
HINT:
Coat the threads of the nuts with engine oil.
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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)
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2600N±04


F45774
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
26±15
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
Dispose the RH side by the same procedures as the LH side.
1. DISPOSE OF SHOCK ABSORBER ASSY FRONT LH
(a) Fully extend the shock absorber rod.
(b) Using a drill, make a hole in the cylinder as shown in theillustration to discharge the gas inside.
CAUTION:

When drilling, chips may fly out. Work carefully.

The gas is colorless, odorless and non±poisonous.
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260DP±01
F44614
Front Shock Absorber with Coil Spring
Front Stabilizer Link Assy LH
47 (479, 35)
220 (2,240, 162)
74 (755, 55)
19 (194, 14)
Speed Sensor
Front LH
Front Flexible Hose
Front Suspension Support Dust Cover LH
Front Suspension Support Sub±assy LH
Front Suspension
Support LH Dust Seal
Front Coil Spring
Seat Upper LH
Front Axle Assy
Front Coil Spring Insulator Upper LH
Front Coil Spring LH
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Front Spring
Bumper LH
Front Coil
Spring Insulator
Lower LH
Shock Absorber
Assy Front LH
39 (398, 29)


26±2
±
FRONT SUSPENSION FRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
COMPONENTS
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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 SUSPENSION FRONT SUSPENSION
26±3
AVENSIS REPAIR MANUAL (RM1018E)
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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 SUSPENSION FRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
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F45154
Rack & Pinion
Power Steering Gear AssyTie 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 RH Front 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 SUSPENSION FRONT SUSPENSION
26±5
AVENSIS REPAIR MANUAL (RM1018E)
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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
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