SHOCK TOYOTA AVENSIS 2005 Service Owner's Manual

1302Y±03
A77119
A77120
A77121
± INTAKETURBO CHARGER SYSTEM (1CD±FTV)
13±3
AVENSIS REPAIR MANUAL (RM1018E)
TURBO CHARGER SYSTEM (1CD±FTV)
PRECAUTION
1. MAINTENANCE PRECAUTION
(a) Do not stop the engine immediately after pulling a trailer,
or after driving at a high speed, or uphill drive. Let the en-
gine Idle for 20 to 120 seconds before turn the ignition
switch OFF (According as the driving condition, the idling
time varies).
(b) Avoid quick acceleration or quickly accelerating the en-
gine RPM immediately after the starting a cold engine.
(c) If the turbocharger is found to be defective, it must be re-
placed. Also, inspect a source of the trouble including
conditions of the turbocharger that having been used. Re-
pair or replace the followings as necessary:
(1) Engine oil (Level and quality)
(2) Oil lines leading to the turbocharger
(d) Pay due attention when removing and reinstalling the
turbocharger assembly. Do not drop, or do not give shock,
or do not grasp easily±deformed assembly parts such as
the actuator or push rod in removal and reinstallation.
(e) Before removal, cover both the intake and exhaust ports
and the oil inlet to prevent dirt or foreign objects from be-
ing introduced.
(f) If replacing the turbocharger, check for deposits in the oil
pipe. If necessary, replace the oil pipe too.
(g) Thoroughly remove old gasket sticking to the lubrication
oil pipe flange and the turbocharger oil flange.
(h) If replacing the bolt(s) or nut(s), must use Toyota genuine
parts to prevent breakage or deformation.
(i) If replacing the turbocharger, put 20 cm
3 (1.2 cu in.) of
fresh oil into the turbocharger oil inlet hole and turn the tur-
bine wheel by hand to spread oil to the bearing.
(j) If overhauling or replacing the engine, cut the fuel supply
after reassembly and crank the engine for 30 seconds to
feed oil throughout the engine then run the engine at idle
for 60 seconds.

260DP±01
F44614
Front Shock Absorber with Coil Spring
Front Stabilizer Link Assy LH
47 (479, 35)
220 (2,240, 162)
74 (755, 55)
19 (194, 14)
Speed Sensor
Front LH
Front Flexible Hose
Front Suspension Support Dust Cover LH
Front Suspension Support Sub±assy LH
Front Suspension
Support LH Dust Seal
Front Coil Spring
Seat Upper LH
Front Axle Assy
Front Coil Spring Insulator Upper LH
Front Coil Spring LH
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Front Spring
Bumper LH
Front Coil
Spring Insulator
Lower LH
Shock Absorber
Assy Front LH
39 (398, 29)

26±2
± FRONT SUSPENSIONFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
COMPONENTS

F44616
89 (908, 66)
102 (1,040, 75)
220 (2,240, 162)
8 (82, 71 in.
lbf)
49 (500, 36)
103 (1,050, 76)
216 (2,200, 159)
Front Shock Absorber with Coil Spring
Front Drive Shaft Assy LHSpeed Sensor Front LH
Cotter Pin
Front Disc
Tie Rod End
Sub±assy LH
Cotter Pin
Front Disc Brake
Caliper Assy LH
Front Suspension Arm
Sub±assy Lower No.1 LH
Lower Ball Joint Assy Front LH
Front Axle Assy LHFront Axle Hub LH Nut
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part



26±4
± FRONT SUSPENSIONFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)

2600K±06
±
FRONT SUSPENSION FRONT SUSPENSION SYSTEM
26±1
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION SYSTEM
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/pulls
4. Tire (Worn or improperly inflated)
5. Wheel alignment (Incorrect)
6. Steering linkage (Loose or worn)
7. Hub bearing (Worn)
8. Steering gear (Out of adjustment or broken)
9. Suspension parts (Worn)28±1
26±6
±
30±2
51±28
51±36
±
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)±
26±10
26±10
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28±1
26±26
26±10
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loose or worn)
8. Steering gear (Out of adjustment or broken)28±1
28±1
26±10 26±6
26±24
30±2 ±
51±28
51±36
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28±1
26±6
26±10 ±

270E2±01
G23870
27±14
± REAR SUSPENSIONREAR 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.

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.

G25775
G23865
G23866
G23867
G23868
± REAR SUSPENSIONREAR 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.

C95735SST

C95736




G24415
Rear shock
absorber
cushion
No.1
Rear
suspension
support
assy LH
G23869
F40128
SST 27±10
± REAR SUSPENSIONREAR 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.


G24416
C96135
Front
23.7

C95738
G23866
G23865
± REAR SUSPENSIONREAR 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.

G23868
G23867
G25772
G25771
27±12
± REAR SUSPENSIONREAR 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.