wheel torque TOYOTA AVENSIS 2003 Service Manual PDF

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)
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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)
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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.
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F44962
+
±
F13685
1
2
F12938
Bolt
Adjusting
Value Set Bolt
Adjusting Bolt90105±17008 90105±17009
90105±17010 90105±17011
121212121 Dot
2 Dots3 Dots
±1
30' ± ±1 15'
±1 15' ± ±1 00'
±1 00' ± ±45'
±45' ± ±30'
±30' ± ±15'
0' ± 15'
15' ± 30'
30' ± 45'
45' ± 1

1 00' ± 1 15'
±15' ± 0'
1 15' ± 1 30'
±
FRONT SUSPENSION FRONT WHEEL ALIGNMENT
26±9
AVENSIS REPAIR MANUAL (RM1018E)
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
(f) Tighten the nuts. Torque: 220 N
m (2,240 kgf
cm, 162 ft
lbf)
(g) Install the front wheel. Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
HINT:

Adjust the camber to the center of the specified value as
much as possible.

Adjusting value for the set bolts is 6' ± 30' (0.1  ± 0.5 ).
If the camber is not within the specified value, using the follow-
ing table, estimate how much additional camber adjustment will
be required, and select the camber adjusting bolt.
NOTICE:
Tighten the adjusting bolt with a washer and a new nut.
(i) Perform the procedure mentioned above again. At step (b), replace 1 or 2 selected bolts.
HINT:
When replacing the 2 bolts, replace 1 bolt for each time.
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260DS±01
G22708
F40228
SST
ZX1712
26±24
±
FRONT SUSPENSION LOWER BALL JOINT ASSY FRONT LH
AVENSIS REPAIR MANUAL (RM1018E)
LOWER BALL JOINT ASSY FRONT LH
REPLACEMENT
HINT:

COMPONENTS: See page 26±2

Replace the RH side by the same procedures as the LH side. 1. INSPECT LOWER BALL JOINT ASSY FRONT LH
(a) Jack up front side of the vehicle.
(b) Check that there is no looseness on the ball joint by shak-ing the lower arm up and down with a force of 294 N (30
kgf, 66 lbf).
2. REMOVE FRONT WHEEL
3.SEPARATE FRONT AXLE HUB LH NUT (See page 30±6) SST 09930±00010
4.DISCONNECT SPEED SENSOR FRONT LH (See page 30±6)
5.SEPARATE FRONT DISC BRAKE CALIPER ASSY LH (See page 30±22)
6. REMOVE FRONT DISC
7.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±22) SST 09628±62011
8.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±22)
9.REMOVE FRONT AXLE ASSY LH (See page 30±22)
10. REMOVE LOWER BALL JOINT ASSY FRONT LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the lower ball joint assy front LH.
11. INSPECT LOWER BALL JOINT ASSY FRONT LH
(a) As shown in the illustration, flip the ball joint stud back andforth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate of 3 ± 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)
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±
FRONT SUSPENSION LOWER BALL JOINT ASSY FRONT LH
26±25
AVENSIS REPAIR MANUAL (RM1018E)
12. INSTALL LOWER BALL JOINT ASSY FRONT LH
(a) Install the lower ball joint assy front LH, and torque the nut.
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b) Install a new cotter pin.
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut further\
up to 60
.
13.INSTALL FRONT AXLE ASSY LH (See page 30±22)
14.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±22)
15.INSTALL TIE ROD END SUB±ASSY LH (See page 30±22)
16. INSTALL FRONT DISC
17.INSTALL FRONT DISC BRAKE CALIPER ASSY LH (See page 30±22)
18.CONNECT SPEED SENSOR FRONT LH (See page 30±6)
19.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
20. INSTALL FRONT WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
21.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
22. CHECK ABS SPEED SENSOR SIGNAL
(a)w/o VSC: See page 05±699
(b)w/ VSC: See page 05±756
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2600P±03
F44620
G21679
26±26
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
STABILIZER BAR FRONT
REPLACEMENT
HINT:
COMPONENTS: See page 26±2
1. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and front stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut,use a hexagon wrench
(6 mm) to hold the stud.
3. REMOVE FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side. 4. INSPECT FRONT STABILIZER LINK ASSY LH
(a) As shown in the illustration, flip the ball joint stud back andforth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate
of 3 ± 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
5.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
6. SEPARATE TIE ROD END SUB±ASSY RH
SST 09628±62011
HINT:
Separate the RH side by the same procedures as the LH side.
7.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
8. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Separate the RH side by the same procedures as the LH side.
9. SEPARATE 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
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F45155
A
B
F44620
26±28
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
21. INSTALL FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID: Install the front stabilizer bracket No.1 RH and the height
control sensor (Front) with the 3 bolts.
Torque:
Bolt A: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
Bolt B: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b) w/o HID: Install the front stabilizer bracket No.1 RH with the 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
22.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
23.INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
24. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
25. INSTALL 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
26.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
27. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
28.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
29. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side.
30. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the 2 nuts.Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
31. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
32. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
33.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
34.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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G23882
SST
G22395
G23871
G25777
±
REAR SUSPENSION LOWER CONTROL ARM ASSY LH
27±25
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using SST, remove the lower control arm assy LH from
the rear axle carrier sub±assy LH.
SST 09610±20012
NOTICE:
Do not damage the dust cover.
3. INSPECT LOWER CONTROL ARM ASSY LH
(a) Before installing the nut, flip the ball joint stud back and forth 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 at the
5th turn.
Turning torque:
3.0 N
m (31 kgf
cm, 27 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 lower control arm assy LH is not de-
formed.
4. INSTALL LOWER CONTROL ARM ASSY LH
(a) Install the member side lower control arm assy LH, and temporarily tighten bolt.
(b) Install the nut. Torque: 60 N
m (612 kgf
cm, 44 ft
lbf)
(c) Install the clip.
NOTICE:

When the holes for the clip are not aligned, adjust
them by tightening the nut. The tightening angle for
the adjustment must be less than 60 .

Insert the clip from the rear side of a vehicle.
5. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
6.STABILIZE SUSPENSION (See page 27±8)
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G23871
G23906
27±26
±
REAR SUSPENSION LOWER CONTROL ARM ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
7. FULLY TIGHTEN LOWER CONTROL ARM ASSY LH
(a) Fully tighten the bolt. Torque: 105 N
m (1,071 kgf
cm, 77 ft
lbf)
(b) RH side (w/ Height control sensor): Install the height control sensor sub±assy and nut to the
lower control arm assy RH.
Torque: 5.8 N
m (59 kgf
cm, 51 in.
lbf)
(c) RH side (w/ Height control sensor): Headlight aim only (See page 65±19).
8.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
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