wheel torque TOYOTA AVENSIS 2003 Service Repair Manual

F40024
A
B
G23166
32±60
±
BRAKESPEED SENSOR FRONT LH
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the sensor harness clamp with the 2 bolts ºAº and ºBº to the body and shock absorber.
Torque:
Bolt A: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
Bolt B: 29 N
m (296 kgf
cm, 21 ft
lbf)
NOTICE:
Do not twist the sensor wire when installing the sensor.
(c)Connect the speed sensor connector.
(d)Connect the resin clip and speed sensor wire harness to the body and clamp.
5.INSTALL FRONT FENDER LINER LH
6.INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
7.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)
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F44823
RH
LH
Front Front
F44708
Expand
Contract
33±18
±
PARKING BRAKE PARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
16. CHECK PARKING BRAKE INSTALLATION
(a) Check that each part is installed properly.
NOTICE:
There should be no oil or grease on the friction surface of the shoe lin\
ing and disc.
17. INSTALL REAR DISC 18. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expandthe shoes until the disc locks.
(c) Contract the shoe adjuster until the disc can rotate smoothly.
Standard : Return 8 notches
(d) Check that there is no brake drag.
(e) Install the hole plug.
19. CONNECT 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)
20. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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33±12
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
17.APPLY HIGH TEMPERATURE GREASE (See page 33±14)
18.INSTALL PARKING BRAKE SHOE LEVER LH (See page 33±14)
19.INSTALL PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
20.INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (See page 33±14)
21.INSTALL PARKING BRAKE ADJUSTER KIT (See page 33±14)
22. INSTALL REAR DISC
23.CONNECT REAR DISC BRAKE CALIPER ASSY LH(See page 30±31)
24.ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33±14)
25. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
26.SETTLING PARKING BRAKE SHOES AND DISC (See page 33±14)
27.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
28.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
29. CHECK EXHAUST LEAKAGE
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3300F±07
F44808
Lock NutAdjusting Nut
33±2
±
PARKING BRAKE PARKING BRAKE SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. REMOVE REAR WHEEL
2.ADJUST PARKING BRAKE SHOE CLEARANCE (See page 33±14)
3. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
4. INSPECT PARKING BRAKE LEVER TRAVEL
(a) Pull the parking brake lever all the way up, and count the number of cli\
cks. Parking brake lever travel: 6 ± 9 clicks at 196 N (20 kgf, 44.1 lbf)\
5. ADJUST PARKING BRAKE LEVER TRAVEL
(a) Remove the console box assy RR.(See page71±11)
(b) Loosen the lock nut and turn the adjusting nut until the le- ver travel turns correct.
(c) Tighten the lock nut. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(d) Install the console box assy RR.
(See page 71±11)
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41046±11
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
41±3
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (C50/C250)
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
6.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
7. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST(s), remove the oil seal.SST 09308±00010
8. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
9. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 1.9
0.3 mm (0.075
0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
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D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±4
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 9.9
0.3 mm (0.390
0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
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41046±12
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
41±5
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (E354/E357)
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
6.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
7. REMOVE FRONT TRANSAXLE CASE COVER OILSEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
8. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
9. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal.
SST 09608±10010, 09950±70010 (09951±07200)
Drive in depth: 0
0.5 mm (0
0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.
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D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±6
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09608±32010, 09950±70010 (09951±07200)
Drive in depth: 3.5
0.5 mm (0.138
0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts)
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
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410DU±01
D30480
D30081
41±24
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER SUB±ASSY NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19.REMOVE STARTER ASSY (See page 19±12) 20. SEPARATE WIRE HARNESS
(a) Remove the 3 bolts, and separate the 3 wire harnesses.
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D30080
41±30
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts. Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Nut: 3.5 N
m (36 kgf
cm, 31 in.
lbf)
59. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
60. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUB±ASSY Torque: 13 N
m (132 kgf
cm, 10 ft
lbf)
64.INSPECT HOOD SUB±ASSY (See page 75±2)
65.ADJUST HOOD SUB±ASSY (See page 75±2)
66.ADD TRANSAXLE OIL (See page 41±5)
67.INSPECT TRANSAXLE OIL (See page 41±2)
68. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
69.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
70.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page)See page 50±9)
71.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
72.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76.BLEED POWER STEERING FLUID (See page 51±4)
77.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
78.INSPECT FLUID LEAK (See page 51±4)
79.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
83.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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