TOYOTA AVENSIS 2003 Service Repair Manual

G23877
G23886
Outward
Inward
Longer Shorter Inward
Outward
Front Longer
Shorter
CAMBER ADJUSTING CAM ASSY
TIE ROD ADJUSTING TUBE
±
REAR SUSPENSION REAR WHEEL ALIGNMENT
27±5
AVENSIS REPAIR MANUAL (RM1018E)
(d) Loosen the camber adjusting cam assy set nut.
(e) Loosen the tie rod adjusting tube set nut.
(f) Adjust the camber and toe±in by turning the adjusting
cam and adjusting tube.
HINT:
Adjust the camber and toe±in to the center of the specified val-
ues as much as possible.
Toe±in:
(Normal package)
Toe±in (total)A + B: 0' \b 6' (0.3  \b 0.1 )
C ± D: 3.0
1.0 mm (0.12
0.04 in.)
(Rough road package)
Toe±in
(total)A + B: 0' \b 6' (0.3  \b 0.1 )
C ± D: 3.0
1.0 mm (0.12
0.04 in.)
Camber:
(Normal package)
Camber
Right±left error±0 ' \b 20' (±0.9  \b 0.3 )
30' (0.5 ) or less
(Rough road package)
Camber
Right±left error±0
' \b 20' (±0.5  \b 0.3 )
30' (0.5 ) or less
(g) Tighten the camber adjusting cam assy set nut.
Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
(h) Tighten the tie rod adjusting tube set nut. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
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G23890
Example:Camber
To e
1
00'
(1.0
)
(Scale) 0 2 4 6
27±6
±
REAR SUSPENSION REAR WHEEL ALIGNMENT
AVENSIS REPAIR MANUAL (RM1018E)
(i) How to read an adjustment chart (using examples). (1) Measure the present alignment.
Example:
Camber (RH) : ±1
24' (±1.4
)
Camber (LH) : ±2
24' (±2.4
)
Toe±in (total) : IN 7.0 mm (0.276 in.)
(2) Mark the difference between the standard value (A) and the measured value (B) on the adjustment
chart.
Standard value:
Camber: ±0
54' (±0.9
)
Toe±in (total) : IN 3.0 mm (0.12 in.)
Formula: A ± B = C
Camber: (RH) : ±0
54' ± (±1
24') = 0
30'
Camber: (LH) : ±0
54' ± (±2
24') = 1
30'
Toe±in (total) : IN 3.0 ± IN 7.0 = OUT 4.0
Toe±in (each side) : OUT 2.0
(3) As shown in the example chart, read the distance
from the marked point to the center of the chart, and
adjust the upper and/or lower arm adjusting cams
accordingly.
Amount to turn camber adjusting cam assy (by gradu-
ation) :
Scale (RH) : ± (Inward) 1.5
Scale (LH) : ± (Inward) 5.5
Amount to turn tie rod adjusting tube (by graduation):
Angle (RH) : ± (Shorter) 96

Angle (LH) : ± (Shorter) 108

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G23889
Camber
To e
Longer
Tie Rod
Adjusting Tube Shorter
InwardCamber Adjusting
Cam Assy Outward
±
REAR SUSPENSION REAR WHEEL ALIGNMENT
27±7
AVENSIS REPAIR MANUAL (RM1018E)
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270E6±01
G25774
C66721
G23876
±
REAR SUSPENSION STABILIZER BAR REAR
27±29
AVENSIS REPAIR MANUAL (RM1018E)
STABILIZER BAR REAR
REPLACEMENT
HINT:
COMPONENTS: See page 27±2.
1. REMOVE REAR STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and 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.
2. REMOVE REAR STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side. 3. INSPECT REAR STABILIZER LINK ASSY LH
(a) Before installing the nut, flip the ball joint stud back andforth 5 times as shown in the illustration.
(b) Using a torque wrench, continuously turn the nut for 2 to
4 seconds per 1 turn, and take the torque reading on the
5th turn.
Turning torque:
1.0 N
m (10 kgf
cm, 8.7 in.
lbf) or less
NOTICE:

Neither unusual drag nor rattle occurs during the
rotation.

Neither crack nor grease leakage exists on the dust
cover.

Make sure that rear stabilizer link assy LH is not de-
formed.
4. REMOVE STABILIZER BAR REAR
(a) Remove the 2 bolts, 2 nuts and 2 rear stabilizer bar brack- et No.3 from the rear suspension member sub±assy.
(b) Remove the 2 stabilizer bush rear from each stabilizer bar rear.
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G23878
Inner side
Stopper Ring
G23876
G25774
27±30
±
REAR SUSPENSION STABILIZER BAR REAR
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL STABILIZER BAR REAR
(a) Install the 2 stabilizer bush rear to each stabilizer bar rear.
HINT:
Install the stabilizer bush rear to the outer side of the stopper
ring on the stabilizer bar.
(b) Install the stabilizer bar rear and 2 rear stabilizer bar bracket No.3 with 2 bolts and 2 nuts.
Torque: 35 N
m (357 kgf
cm, 26 ft
lbf)
6. INSTALL REAR STABILIZER LINK ASSY LH
(a) Install the rear stabilizer link assy LH with the 2 nuts. 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.
7. INSTALL REAR STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
8.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
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270E5±01
G25775
G21542
G23879
Matchmarks
G23879
Matchmarks
±
REAR SUSPENSION UPPER CONTROL ARM ASSY
27±27
AVENSIS REPAIR MANUAL (RM1018E)
UPPER CONTROL ARM ASSY
REPLACEMENT
HINT:
COMPONENTS: See page 27±2.
1. REMOVE REAR WHEEL
2. REMOVE UPPER CONTROL ARM ASSY
(a) Support the rear suspension arm assy No.1 LH.
(b) Remove the bolt and nut, separate the upper control armassy.
NOTICE:
When removing the bolt, hold the nut not to rotate.
(c) Place matchmarks on the camber adjust cam assy, cam- ber adjust cam No.2 and rear suspension member sub±
assy.
(d) Remove the nut, camber adjust cam assy and camber ad-
just cam No.2.
3. INSTALL UPPER CONTROL ARM ASSY
(a) Install the camber adjust cam assy from the front side of the vehicle, and temporarily fix it with the nut and the cam-
ber adjust cam No.2.
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G21542
G21542
G23879
Matchmarks
27±28
±
REAR SUSPENSION UPPER CONTROL ARM ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the upper control arm assy, and temporarily tighten the bolt and nut.
4. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
5.STABILIZE SUSPENSION (See page 27±8)
6. FULLY TIGHTEN UPPER CONTROL ARM ASSY
NOTICE:
Be sure to empty the vehicle when fully tightening the bolt
and nut.
(a) Fully tighten the bolt and nut.Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
NOTICE:
When instaling the bolt, hold the nut not to rotate.
(b) Align the matchmarks, and fully tighten the nut. Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
7.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
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2801F±02
R03031


F45650
Front
(A)
(B)
±
TIRE & WHEEL WHEEL AND TIRE SYSTEM
28±1
AVENSIS REPAIR MANUAL (RM1018E)
WHEEL AND TIRE SYSTEM
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure:
3ZZ ± FE, 1ZZ ± FE, 1AZ ± FE engine models:
Tire sizeFront
kPa (kgf
cm2, psi)
Rear
kPa (kgf
cm2, psi)
195/65R16 91V, 205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
220 (2.2, 32) *1 240 (2.4, 35) *2
220 (2.2, 32) *1 250 (2.5, 36) *2220 (2.2, 32) *1 240 (2.4, 35) *2
220 (2.2, 32) *1 280 (2.8, 41) *2
1CD ± FTV engine models:
Tire sizeFront
kPa (kgf
cm2, psi)
Rear
kPa (kgf
cm2, psi)
205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
240 (2.4, 35) *1 270 (2.7, 39) *2
240 (2.4, 35) *1 280 (2.8, 41) *2240 (2.4, 35) *1 270 (2.7, 39) *2
240 (2.4, 35) *1 290 (2.9, 42) *2
1AZ ± FSE engine models:
Tire sizeFront
kPa (kgf
cm2, psi)
Rear
kPa (kgf
cm2, psi)
205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
215/45R17 87W: with 4 or less occupants
with 5 or more occupants220 (2.2, 32) *1 250 (2.5, 36) *2
220 (2.2, 32) *1 270 (2.7, 39) *2
240 (2.4, 35) *1 290 (2.9, 42) *2
240 (2.4, 35) *1 310 (3.1, 45) *2
220 (2.2, 32) *1 250 (2.5, 36) *2
220 (2.2, 32) *1 280 (2.8, 41)*2
240 (2.4, 35) *1 290 (2.9, 42) *2
240 (2.4, 35) *1 330 (3.3, 48) *2
*1: For driving under 160 km/h (100 mph)
*2: For driving at 160 km/h (100 mph) or over
(b) Using a dial indicator, check the runout of tires.Tire runout: 1.4 mm (0.055 in.) or less
2. ROTATE TIRE
HINT:
If the spare tire is the same as ground tire, perform as ºAº in the
illustration, and if the spare tire is compact tire, perform as ºBº
in the illustration.
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C80976
28±2
±
TIRE & WHEEL WHEEL AND TIRE SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
3. INSPECT WHEEL BALANCE
(a) Check and adjust the Off±the±car balance.
(b) If required, check and adjust the On±the±car balance. Imbalance after adjustment: 8.0 g (0.018 lb) or less
4.INSPECT BEARING BACKLASH (See page 30±2)
5.INSPECT AXLE HUB DEVIATION (See page 30±2)
6.INSPECT BEARING BACKLASH (See page 30±2)
7.INSPECT AXLE HUB DEVIATION (See page 30±2)
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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
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