TOYOTA AVENSIS 2003 Service Repair Manual

300JW±01
F44751
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable parts

Front Suspension
Arm Sub±assy No.1 LH







89 (908, 66)
19 (194, 14)
74 (755, 55)
64 (650, 47)
49 (500, 36)
216 (2,200, 159)

Front Axle Hub LH Nut
Flexible Hose
Tie Rod End Sub±assy


Cotter Pin


Front Drive Shaft RH
Hole Snap Ring
Front Drive Shaft Assy RH
Front Drive Shaft Assy RH
1AZ±FSE/
1AZ±FE/
1CD±FTV:
Speed Sensor Front LH
8.0 (82, 71 in.

lbf)
Front Drive Shaft Assy LH
Front Stabilizer Link Assy LH
3ZZ±FE/
1ZZ±FE:
64 (650, 47)
Front Drive Shaft Assy LH
3ZZ±FE/
1ZZ±FE/
1AZ±FSE (AT)/
1AZ±FE (AT):
1AZ±FSE (MT)/
1AZ±FE (MT)/
1CD±FTV:

Front Drive Shaft LH
Hole Snap Ring

Front Drive Shaft LH
Hole Snap Ring
±
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT
30±3
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DRIVE SHAFT
COMPONENTS
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F45574Non±reusable parts



Front Drive Shaft Dust Cover LH
Front Drive Inboard Joint Assy LH
Front Drive Inner Shaft
Inner LH Shaft Snap Ring Front Axle Inboard Joint Boot LH Clamp
Drive Shaft Damper
Drive Shaft Damper Clamp
Front Drive Shaft Inboard
Joint Boot
Front Axle Inboard Joint Boot LH No.2 Clamp
Tripod Joint Assy








Front Drive Shaft Out board Joint Boot
Front Axle Outboard Joint Boot LH No.2 Clamp


Front Drive Outboard Joint Shaft Assy LH
Front Axle Outboard
Joint Boot LH Clamp
LH:
Except
1AZ±FSE (MT)/
1AZ±FE (MT)/
1CD±FTV:




30±4
±
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
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F45575Non±reusable parts


Front Axle Outboard Joint Boot RH No.2 Clamp
Drive Shaft Outboard Joint BootFront Axle Out board Joint Boot RH Clamp
Drive Shaft DamperFront Axle Inboard Joint Boot RH Clamp
Drive Shaft Inboard Joint Boot
Front Axle Inboard Joint
Boot RH No.2 Clamp




Front Drive Outboard Joint Shaft Assy RH
RH:
3ZZ±FE/
1ZZ±FE: 1AZ±FSE/
1AZ±FE/
1CD±FTV:
Front Drive Inboard
Joint Assy RH
Front Drive Shaft
Dust Cover RH Tripod Joint Assy
Front Drive Inner
Shaft Inner RH
Shaft Snap Ring
Drive Shaft Bearing
Case Snap Ring
Front Drive Shaft Bearing
Straight Pin
Drive Shaft Bearing Case Front Drive Shaft
Hole Snap RingFront Drive Shaft
Dust Cover Front Drive Shaft
Dust Cover RH














3ZZ±FE/
1ZZ±FE:
1AZ±FSE/
1AZ±FE/
1CD±FTV:
Front Drive Inboard
Joint Assy RH






±
DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT
30±5
AVENSIS REPAIR MANUAL (RM1018E)
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30093±02

F45576
Skid Control Sensor Wire
5.0 (51, 44 in.
lbf)
Upper Control Arm Assy LH

Clip
74 (755, 55)
60 (612, 44)Lower Control Arm Assy LH
Parking Brake Shoe
Rear Disc
47 (475, 34)
Rear Disc Brake Caliper Assy LH

Clip
105 (1,071, 77)
Parking Brake Shoe
140 (1,428, 103)
56 (571, 41)
Rear Axle Carrier Sub±assy LH
Rear Axle Hub & Bearing Assy LH
Rear Axle Hub Bolt
x4
N

m (kgf
cm, ft
lbf) : Specified torque

Non±reusable parts Parking Brake Cable
Assy No.3
Parking Brake Shoe
Adjusting Screw Set
Parking Brake Adjuster Kit
Parking Brake Shoe Lever LH
74 (755, 55)
Back Plate Assy LH
30±30
±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
REAR AXLE CARRIER SUB±ASSY LH
COMPONENTS
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300JZ±01
F45267
F44818

F45752
SST
±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB±ASSY LH
30±31
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replace the RH side by the same procedures as the LH side.
1. INSPECT REAR AXLE CARRIER SUB±ASSY LH
(a) Check that there is no looseness on the ball joint by shaking the lower arm up and down with a force
of 294 N (30kgf, 66 lbf).
2. REMOVE REAR WHEEL
3. DISCONNECT SKID CONTROL SENSOR WIRE
(a) Remove the bolt, disconnect the skid control sensor wire.
(b) Disconnect the connector.
4. SEPARATE REAR DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts and rear disc brake caliper assy.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down\
.
5. REMOVE REAR DISC
6.REMOVE PARKING BRAKE ADJUSTER KIT (See page 33±14)
7.REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (See page 33±14)
8.REMOVE PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
9.REMOVE PARKING BRAKE SHOE LEVER LH (See page 33±14)
10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Using needle±nose pliers, and disconnect the parkingbrake cable assy No.3 from the backing plate.
11. SEPARATE LOWER CONTROL ARM ASSY LH
(a) Loosen the lower control arm assy bolt (member side).
(b) Remove the clip and nut.
(c) Using SST, separate the lower control arm assy from the axle carrier.
SST 09610±20012
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F45753HoldTurn
SST
G21537
G21542
G20965
30±32
±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
12. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH
(a) Remove the clip and nut.
(b) Using SST, separate the rear suspension arm assy No.1 (ball joint side).
SST 09628±62011
(c) Remove the bolt and nut, separate the rear suspension arm assy No.1.
NOTICE:
When removing the bolt, hold the nut not to rotate.
13. SEPARATE UPPER CONTROL ARM ASSY
(a) Remove the bolt and nut, separate the upper control arm assy from the axle carrier.
NOTICE:
When removing the bolt, hold the nut not to rotate.
14. REMOVE REAR AXLE CARRIER SUB±ASSY LH
(a) Remove the 4 bolts and nut, hub & bearing assy and axle carrier sub±assy.
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G21613
G20965
G21542
G21537
±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB±ASSY LH
30±33
AVENSIS REPAIR MANUAL (RM1018E)
15. INSPECT REAR AXLE CARRIER SUB±ASSY LH
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate of 3 ± 5 seconds per turn and take the torque reading on
the 5th turn.
Turning torque (Maximum):
3.0 N
m (30 kgf
cm, 27 in.
lbf)
NOTICE:

Neither abnormal drag nor rattle exists during the
rotation.

Neither crack nor grease leakage exists and deforma-
tion on the dust cover.
16. INSTALL REAR AXLE CARRIER SUB±ASSY LH
(a) Install the hub & bearing assy and rear axle carrier sub± assy with the 4 bolts and nut.
Torque:
Bolt: 56 N
m (571 kgf
cm, 41 ft
lbf)
Nut: 140 N
m (1,428 kgf
cm, 103 ft
lbf)
17. TEMPORARILY TIGHTEN U PPER CONTROL ARM
ASSY
(a) Temporarily tighten the upper control arm assy with the bolt and nut.
Temporarily tighten torque:
7 ± 13 N
m (71 ± 133 kgf
cm, 5.1 ± 9.6 ft
lbf)
HINT:
Insert the bolt from the rear side of the vehicle and temporarily
install the bolt.
18. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH
(a) Temporarily tighten the rear suspension arm assy (ball
joint side) with the nut.
(b) Temporarily tighten the bolt and nut. Temporarily tighten torque:
7 ± 13 N
m (71 ± 133 kgf
cm, 5.1 ± 9.6 ft
lbf)
HINT:
Insert the bolt from the rear side of the vehicle and temporarily
install the bolt.
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G21543
F44820


F45267
30±34
±
DRIVE SHAFT / PROPELLER SHAFTREAR AXLE CARRIER SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
19.TEMPORARILY TIGHTEN LOWER CONTROL ARM ASSY LH
(a)Temporarily tighten the lower control arm assy with the
nut.
Temporarily tighten Torque:
7 ± 13 N
m (71 ± 133 kgf
cm, 5.1 ± 9.6 ft
lbf)
20.CONNECT PARKING BRAKE CABLE ASSY NO.3
(a)Connect the parking brake cable assy No.3 to the backing plate.
21.INSTALL PARKING BRAKE SHOE LEVER LH (See page 33±14)
22.INSTALL PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
23.INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (See page 33±14)
24.INSTALL PARKING BRAKE ADJUSTER KIT (See page 33±14)
25.CHECK PARKING BRAKE INSTALLATION (See page 33±14)
26.INSPECT BEARING BACKLASH (See page 30±2)
27.INSPECT AXLE HUB DEVIATION (See page 30±2)
28. INSTALL REAR DISC
29.ADJUST PARKING BRAKE SHOE CLEARANCE (See page 33±14)
30. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
31. CONNECT SKID CONTROL SENSOR WIRE
(a) Connect the skid control sensor wire with the bolt. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(b) Connect the connector.
HINT:
Do not twist the sensor wire when installing the sensor.
32. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
33.STABILIZE SUSPENSION (See page 27±8)
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±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE CARRIER SUB±ASSY LH
30±35
AVENSIS REPAIR MANUAL (RM1018E)
34. FULLY TIGHTEN UPPER CONTROL ARM ASSY
(a) Fully tighten the bolt.
Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
NOTICE:
When installing the bolt, hold the nut not to rotate.
35. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH
(a) Fully tighten the nut (ball joint side). Torque: 105 N
m (1,071 kgf
cm, 77 ft
lbf)
(b) Install the clip.
NOTICE:
If the holes for the clip are not aligned, tighten the nut up to 60
further.
(c) Fully tighten the bolt and nut.
Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
NOTICE:
When installing the bolt, hold the nut not to rotate.
36. FULLY TIGHTEN LOWER CONTROL ARM ASSY LH
(a) Fully tighten the nut. Torque: 60 N
m (612 kgf
cm, 44 ft
lbf)
(b) Install the clip.
NOTICE:
If the holes for the clip are not aligned, tighten the nut up to 60
further.
(c) Fully tighten the bolt (member side). Torque: 105 N
m (1,071 kgf
cm, 77 ft
lbf)
NOTICE:
When installing the bolt, hold the nut not to rotate.
37.INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
38.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
39. 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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300K0±01

F45577
Hold
Turn
SST

F45578
Hold
Turn
Nut
Washer
30±36
±
DRIVE SHAFT / PROPELLER SHAFT REAR AXLE LH HUB BOLT
AVENSIS REPAIR MANUAL (RM1018E)
REAR AXLE LH HUB BOLT
REPLACEMENT
HINT:

COMPONENTS: See page 30±30

Replace the RH side by the same procedures as the LH side.
1. REMOVE REAR WHEEL
2. SEPARATE REAR DISC BRAKE CALIPER ASSY LH
(a) Removing the 2 bolts and rear disc brake caliper assy.
NOTICE:
Use a string or other device to keep the brake caliper from hanging down\
.
3. REMOVE REAR DISC
4. REMOVE REAR AXLE LH HUB BOLT
(a) Turn the axle hub to move the LH hub bolt and SST, thatare to be removed, to the place shown in the illustration.
NOTICE:
Do not replace the hub bolt in any places other than that in
the illustration.
(b) Using SST and a hammer handle or an equivalent to hold the axle hub, remove the LH hub bolt.
SST 09628±10011
5. INSTALL REAR AXLE LH HUB BOLT
(a) Install a washer and nut to a new LH hub bolt as shown in the illustration.
(b) Using a hammer handle or an equivalent to hold the axle
hub, install the LH hub bolt by torquing the nut.
6. INSTALL REAR DISC
7. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper assy with the 2 bolts. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
8. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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