TOYOTA AVENSIS 2003 Service Repair Manual

C95317
C86742
C87504
C95318
±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)26±17
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE FRONT SUSPENSION MEMBER B RACE
REAR LH
(a) Support the front suspension crossmember sub±assy
with a transmission jack.
(b) Remove the 4 bolts and front suspension member brace rear LH.
(c) Remove the front suspension member body mounting
stopper rear from the front suspension member brace
rear LH.
11. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Remove the RH side by the same procedures as the LH side.
12. SEPARATE FRONT SUSPENSION CROSSMEMBERSUB±ASSY
(a) w/ HID: Disconnect the height control sensor (Front) connector.
(b) Remove the 3 bolts and 3 nuts, disconnect the transverse
engine engine mounting insulator and engine mounting
member sub±assy center from the front suspension
crossmember sub±assy.
(c) Remove the 2 nuts and 2 front suspension member body mounting stoppers front.
(d) Lower the transmission jack, remove the front suspension crossmember sub±assy.
13. 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.
http://vnx.su

C95318
C87504
C86742
AA
AAB
B
C95317
AA
A
B
26±18
±
FRONT SUSPENSIONFRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH(ATM)
AVENSIS REPAIR MANUAL (RM1018E)
14.TEMPORARILY TIGHTEN FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a)Install the lower suspension arm sub±assy lower No.1
LH, and temporarily tighten the 2 bolts and nut.
15.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY
(a)Support the front suspension crossmember sub±assy with a transmission jack.
(b)Install the 2 front suspension member body mounting stoppers front and 2 nuts.
Torque: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
(c)Connect the transverse engine engine mounting insula- tor and engine mounting member sub±assy center to the
front suspension crossmember sub±assy.
(d)Install the 3 bolts and 3 nuts. Torque:
Bolt A: 52 N
m (530 kgf
cm, 38 ft
lbf)
Bolt B: 96 N
m (979 kgf
cm, 71 ft
lbf)
(e)w/ HID: Connect the height control sensor (Front) connector.
16.INSTALL FRONT SUSPENSION ME MBER BRACE
REAR LH
(a)Install the front suspension member body mounting stop- per rear to the front suspension member brace rear LH.
(b)Install the 4 bolts and front suspension member brace rear LH.
Torque:
Bolt A: 80 N
m (816 kgf
cm, 59 ft
lbf)
Bolt B: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
17.INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
18.CONNECT 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
http://vnx.su

C80293
F13686
C80889
±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)26±19
AVENSIS REPAIR MANUAL (RM1018E)
19. 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)
20. CONNECT FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
21.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
22. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side. 23. 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.
24. CONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
25. 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\
.
26. FULLY TIGHTEN FRONT SUSPENSION ARMSUB±ASSY LOWER NO.1 LH
(a) Fully tighten the 2 bolts and nut.
Torque: 137 N
m (1,400 kgf
cm, 101 ft
lbf)
http://vnx.su

26±20±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
27.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
http://vnx.su

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.
http://vnx.su

C80889
F41742
F13686
C80889
26±22±
FRONT SUSPENSION FRONT 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 ARMSUB±ASSY LOWER NO.1 LH
(a) Fully tighten the 2 bolts and nut.
Torque: 137 N
m (1,400 kgf
cm, 101 ft
lbf)
http://vnx.su

±
FRONT SUSPENSIONFRONT 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)
http://vnx.su

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 ±
http://vnx.su

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.
http://vnx.su

SA0028
ABFront AB
A: Inside
B: Outside
Z03382
Alignment
Tester Gauge
±
FRONT SUSPENSION FRONT 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 
\b
  \b

 47'  2 
\f
  \b\b
Outside wheel: Reference32 52'  \b
\f
315'  \b
\b
(Rough road package)
Inside wheel
 42'  2 
\f  \b
 09'  2  
  \b\b
Outside wheel: Reference33 16'  \b\f
3138'   \b
*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 error\b54'  45' (2.90   0.75 )
45' (0.75 ) or less
Steering axis inclination
Right±left error\b27'  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 error\b40'  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.
http://vnx.su