TOYOTA AVENSIS 2003 Service Repair Manual

270E8±01
G25771
G25772
27±8
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
REAR SHOCK ABSORBER WITH COIL SPRING
OVERHAUL
HINT:
COMPONENTS: See page 27±2.
1. REMOVE REAR DOOR SCUFF PLATE LH
2. REMOVE REAR SEAT CUSHION ASSEMBLY
(a)40/60 FOLDING FLIP±UP CUSHION (See page 72±21)
(b)40/60 FOLDING (See page 72±27)
(c)UNITED FIXED (See page 72±32)
3. REMOVE REAR SEATBACK ASSY
(a)40/60 FOLDING FLIP±UP CUSHION (See page 72±21)
(b)40/60 FOLDING (See page 72±27)
(c)UNITED FIXED (See page 72±32)
4. REMOVE REAR FLOOR FINISH PLATE (SEDAN MODELS)
5. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH (SEDAN MODELS)
6. REMOVE REAR FLOOR FINISH PLATE (LIFTBACK MODELS)
7.REMOVE DECK TRIM SIDE BOARD LH (LIFTBACK MODELS) (See page 76±45)
8. REMOVE REAR FLOOR FINISH PLATE (WAGON MODELS)
9.REMOVE DECK TRIM SIDE PANEL ASSY LH (WAGON MODELS) (See page 76±54)
10. REMOVE REAR WHEEL 11. DISCONNECT SKID CONTROL SENSOR WIRE
(a) Disconnect the skid control sensor connector.
(b) Remove the bolt and wire bracket.
12. SEPARATE REAR STABILIZER LINK ASSY LH
(a) Remove the nut, and separate the rear stabilizer link assyLH.
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
13. SEPARATE REAR STABILIZER LINK ASSY RH
HINT:
Separate the RH side by the same procedures as the LH side.
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G25775
G23865
G23866
G23867
G23868
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
27±9
AVENSIS REPAIR MANUAL (RM1018E)
14. REMOVE REAR SHOCK ABSORBER WITH COIL
SPRING
(a) Support the rear suspension arm assy No.1 LH.
(b) Remove the bolt and nut from the rear suspension arm assy No.1 LH.
NOTICE:
When removing the bolt, hold the nut not to rotate.
(c) Remove the 3 nuts.
(d) Remove the 2 bolts, and separate the parking brake cable assy No.3.
(e) Remove the 3 bolts from the rear suspension arm assy No.1 LH.
(f) Press the rear suspension arm assy No.1 LH down to the
outside of the vehicle and remove the rear shock absorb-
er with coil spring.
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C95735SST

C95736




G24415
Rear shock
absorber
cushion
No.1 Rear
suspension
support
assy LH
G23869
F40128
SST
27±10
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE SHOCK ABSORBER ASSY REAR LH
(a) Using SST, compress the coil rear spring. SST 09727±30021 (09727±00010, 09727±00021,
09727±00031)
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Using a 6 mm hexagon wrench to hold the piston rod, re- move the nut.
(c) Remove the rear shock absorber cushion washer No.1.
(d) Remove the rear suspension support assy LH.
(e) Remove the rear spring front bracket sub±assy LH.
(f) Remove the rear shock absorber cushion No.1.
(g) Remove the rear spring bumper No.1 LH.
(h) Remove the rear coil spring insulator upper LH.
(i) Remove the coil rear spring.
16. INSPECT SHOCK ABSORBER ASSY REAR LH
(a) Compress and extend the shock absorber rod and check for unusual resistance or unusual sound during the op-
eration.
If there is any malfunction, replace the shock absorber assy
rear LH with a new one.
17. INSTALL SHOCK ABSORBER ASSY REAR LH
(a) Using SST, compress the coil rear spring. SST 09727±30021 (09727±00010, 09727±00021,
09727±00031)
NOTICE:
Do not use an impact wrench. It will damage the SST.
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G24416
C96135
Front23.7

C95738
G23866
G23865
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
27±11
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the coil rear spring to the shock absorber assy rear
LH.
NOTICE:
Fit the lower end of the coil rear spring into the gap of the
spring lower seat.
(c) Install the rear spring bumper No.1 LH and rear suspen- sion support assy LH.
(d) Set the rear coil spring insulator upper LH to the rear spring front bracket sub±assy LH.
(e) Position the rear spring front bracket sub±assy LH with rear coil spring insulator upper LH as shown in the illustra-
tion.
HINT:
Place the RH side on the symmetric position to the illustration.
(f) Install the rear suspension support assy LH and rear shock absorber cushion washer No.1.
(g) Temporarily tighten a new center nut.
(h) Remove the SST.
(i) Recheck the direction of the spring bracket.
(j) Using a 6 mm hexagon wrench to hold the piston rod, tighten a new nut.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
18. INSTALL REAR SHOCK ABSORBER WITH COIL SPRING
(a) Install the 3 nuts. Torque: 80 N
m (816 kgf
cm, 59 ft
lbf)
(b) Install the rear shock absorber with coil spring, and tem- porarily tighten the bolt and nut.
NOTICE:
When installing the bolt, tighten the bolt temporarily with
the nut fixed.
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G23868
G23867
G25772
G25771
27±12
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the rear suspension arm assy No.1 LH with the 3 bolts.
Torque: 65 N
m (663 kgf
cm, 48 ft
lbf)
(d) Connect the parking brake cable assy No.3 with the 2 bolts.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
19. INSTALL REAR STABILIZER LINK ASSY LH
(a) Install the rear stabilizer link assy LH with the nut. Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
20. INSTALL REAR STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side. 21. CONNECT SKID CONTROL SENSOR WIRE
(a) Install the wire bracket and bolt.Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(b) Connect the skid control sensor connector.
22. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
23. STABILIZE SUSPENSION
(a) Bounce the vehicle up and down several times to stabilize the suspension\
.
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G23865
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
27±13
AVENSIS REPAIR MANUAL (RM1018E)
24. FULLY TIGHTEN REAR SHOCK ABSORBER WITH
COIL SPRING
(a) Fully tighten the bolt and nut.
Torque: 160 N
m (1,632 kgf
cm, 118 ft
lbf)
NOTICE:

When installing the bolt, hold the nut not to rotate.

Be sure to empty the vehicle when fully tightening the
bolt and nut.
25.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
26. 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)
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270E2±01
G23870
27±14
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
1. DISPOSE OF SHOCK ABSORBER ASSY REAR LH
(a) Fully extend the shock absorber rod.
(b) Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside the cylinder.
CAUTION:

When drilling, since the fragments may fly out, work
carefully.

The discharged gas is colorless, odorless and non±
poisonous.
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270E0±01

G26285
w/ Height Control Sensor:
5.8 (59, 51 in.
lbf)
80 (816, 59)
Rear Suspension Member Sub±assy
Rear Shock Absorber
Cushion Washer No.1
Coil Rear Spring
Rear Coil Spring Insulator Upper LH
Rear Spring Bumper No.1 LH
Rear Suspension Support Assy LH
Rear Spring Front Bracket
Sub±assy LH
Rear Shock
Absorber Cushion No.1
Lower Control Arm Assy RH
Rear Shock Absorber
Assy LH
160 (1,632, 118)
110 (1,122, 81)
65 (663, 48)
Rear Suspension
Support Stopper
Rear Suspension Arm
Bracket Assy LH
Rear Suspension
Arm Bush No.1
Camber Adjust Cam Assy
Rear Suspension Arm Assy No.1 LH
74 (755, 55)
105 (1,071, 77)
44 (449, 32)
74 (755, 55)
74 (755, 55)
Parking Brake Cable Assy No.3
5.0 (51, 44 in.
lbf)Rear Axle Carrier Sub±assy LH
Skid Control Sensor Wire
74 (755, 55)
Upper Control Arm Assy
Camber Adjust Cam No.2
Lower Control Arm Assy LH
105 (1,071, 77)
5.0 (51, 44 in.
lbf)
60 (612, 44)
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part


56 (571, 41)

56 (571, 41)
Clip
Clip
27±2
±
REAR SUSPENSION REAR SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION
COMPONENTS
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G23885
Rear Stabilizer Link Assy RHStabilizer Bush Rear
Rear Stabilizer Bar
Bracket No.3
Rear Stabilizer
Link Assy LH
Rear Stabilizer Bar Bracket No.3
Stabilizer Bush Rear
Stabilizer Bar Rear
35 (357, 26)
44 (449, 32)
35 (357, 26)
44 (449, 32)
44 (449, 32)
44 (449, 32)
N
m (kgf
cm, ft
lbf) : Specified torque
±
REAR SUSPENSION REAR SUSPENSION
27±3
AVENSIS REPAIR MANUAL (RM1018E)
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270E3±01
G23867
G25771
G25772
G25775
±
REAR SUSPENSION REAR SUSPENSION ARM ASSY NO.1 LH
27±15
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION ARM ASSY NO.1 LH
OVERHAUL
HINT:
COMPONENTS: See page 27±2.
1. REMOVE REAR WHEEL
2. SEPARATE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 2 bolts, and separate the parking brake cableassy No.3.
3. DISCONNECT SKID CONTROL SENSOR WIRE
(a) Disconnect the skid control sensor connector.
(b) Remove the bolt and wire bracket.
4. SEPARATE REAR STABILIZER LINK ASSY LH
(a) Remove the nut, and separate the rear stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
5. REMOVE LOWER CONTROL ARM ASSY LH
(a) Support the rear suspension arm assy No.1 LH.
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