front control arm TOYOTA AVENSIS 2005 Service Repair Manual

02±30
± PREPARATIONDRIVE SHAFT / PROPELLER SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
09610±20012Pitman Arm PullerREAR AXLE CARRIER SUB±ASSY
LH
09628±10011Ball Joint PullerREAR AXLE LH HUB BOLT
FRONT AXLE LH HUB BOLT
09628±62011Boll Joint PullerFRONT AXLE HUB SUB±ASSY LH
REAR AXLE CARRIER SUB±ASSY
LH
FRONT DRIVE SHAFT
09710±04081BaseFRONT DRIVE SHAFT
09718±00010Shoe Hold Down Spring DriverREAR AXLE CARRIER SUB±ASSY
LH
09726±40010Lower Control Shaft Bearing
ReplacerFRONT DRIVE SHAFT
09930±00010Drive Shaft Nut ChiselFRONT AXLE HUB SUB±ASSY LH
FRONT DRIVE SHAFT
09950±00020Bearing RemoverFRONT DRIVE SHAFT
09950±40011Puller B SetFRONT AXLE HUB SUB±ASSY LH
(09951±04020)Hanger 200FRONT AXLE HUB SUB±ASSY LH
(09952±04010)Slide ArmFRONT AXLE HUB SUB±ASSY LH
(09953±04030)Center Bolt 200FRONT AXLE HUB SUB±ASSY LH
(09954±04010)Arm 25FRONT AXLE HUB SUB±ASSY LH

±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B
52
113530
1,15238
83
Clutch release cylinder x manual transaxleBolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body
w/o Air conditioning
RHD (w/ Air conditioning) steering position type
9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket x BodyLHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder blockw/ Air conditioning2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±139)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815

03±18
± SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133
801,356
81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356
81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulator A
B
52
11 3530
1,15238
83
Clutch release cylinder x manual transaxle Bolt A
Bolt B
Bolt C12
9.0
5.0122
92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140

030KC±06
03±40
± SERVICE SPECIFICATIONSDRIVE SHAFT / PROPELLER SHAFT / AXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Front wheel set nut1031,05076
Rear wheel set nut1031,05076
Manual transaxle oil drain plug C50/C250:
E354/E357:39
49400
50029
36
Lower ball joint assy front x Suspension arm sub±assy lower No.18990866
Tie rod end sub±assy x Steering knuckle4950036
Flexible hose and speed sensor front x Shock absorber assy front1919414
Speed sensor front x Steering knuckle8.08271 in.
lbf
Front stabilizer link assy x Shock absorber assy front7475555
Front axle hub nut2162,200159
Disc brake dust cover front x Steering knuckle8.38573 in.
lbf
Lower ball joint assy front x Steering knuckle1031,05076
Front axle assy x Shock absorber assy front2202,243162
Front disc brake caliper assy x Steering knuckle1021,04075
Automatic transaxle fluid drain plug4950036
Drive shaft bearing case x Bearing bracket6465047
Rear axle hub & bearing assy x Rear axle carrier sub±assy5657141
Rear axle carrier sub±assy x Back plate assy1401,428103
Rear axle carrier sub±assy x Skid control sensor wire5.05144 in.
lbf
Rear disk brake caliper assy x Rear axle carrier sub±assy4747534
Rear axle carrier sub±assy x Upper control arm assy7475555
Rear axle carrier sub±assy x Lower control arm assy ball joint side:
member side:60
105612
1,07144
77
Rear axle carrier sub±assy x Rear suspension arm assy ball joint side:
member side:105
741,071
75577
55

031HG±01
± SERVICE SPECIFICATIONSREAR SUSPENSION
03±37
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Hub nut1031,05076
Piston rod set nut5657141
Shock absorber x Body8081659
Shock absorber x Rear suspension arm1601,63211 8
Parking brake cable set bolt5.05144 in.
lbf
Skid control sensor wire harness bracket set bolt5.05144 in.
lbf
Rear suspension arm bracket x body6566348
Rear suspension arm x Rear suspension member7475555
Rear suspension arm bracket x Rear suspension arm11 01,12281
Rear axle carrier (front side) x Rear suspension arm1051,07177
Rear axle carrier (rear side) x Rear suspension arm7475555
Upper control arm x Rear axle carrier7475555
Upper control arm x Suspension member7475555
Lower control arm x Rear axle carrier6061244
Lower control arm x Suspension member1051,07177
Stabilizer bar x Stabilizer link4444932
Stabilizer link x Suspension arm4444932
Stabilizer bar bracket x Suspension member3535726

0313B±05
03±34
± SERVICE SPECIFICATIONSFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
SERVICE DATA
Vehicle height
(Normal package) Front: A *1
± B *2
Rear: D *4 ± C *3
(Rough road package) Front: A *1
± B *2
Rear: D *4 ± C *3
92 mm (3.62 in.)
61 mm (2.40 in.)
72 mm (2.83 in.)
41 mm (1.61 in.)
Toe±in (total)
Rack end length difference0
06'
12' (0.1

0.2
), 1
2 mm (0.04
0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
[Electric motor power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

17'  2

 

32
52' 


42'  2

 

33
16' 

Front wheel align-
ment
Wheel angle
[Oil pressure power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

47'  2
 
 

31
15' 


09'  2


 

31
38' 


Camber
Normal package
Rough road package
Right±left error
±0
34'  45' (±0.57
 0.75
)
±0
19'  45' (±0.32
 0.75
)
45' (0.75
) or less
Caster
Normal package
Rough road package
Right±left error

54'  45' (2.90
 0.75
)

40'  45' (2.67
 0.75
)
45' (0.75
) or less
Steering axis inclination
Normal package
Rough road package
Right±left error
12
27'  45' (12.45
 0.75
)
11
56'  45' (11.93
 0.75
)
45' (0.75
) or less
Front suspensionLower ball joint turning torque0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
*1: Ground clearance of front wheel center
*2: Ground clearance of lower suspension arm front bolt center
*3: Ground clearance of toe control arm inner bolt center
*4: Ground clearance of rear wheel center

030G7±04
03±60
± SERVICE SPECIFICATIONSPOWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedN
mkgf
cmft
lbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356
81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in.
lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)

+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Case 1
Case 2
Case 3
Case 4
Output voltage of heated oxygen
sensor (sensor 1: front sensor)
Injection volume
Output voltage
Output voltage of heated oxygen
sensor (sensor 2: rear sensor)Mainly suspect
trouble area
OK
+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Injection volume
Output voltage
+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Injection volume
Output voltage
Sensor 1: front sensor
(sensor 1, heater, sensor 1
circuit)
+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Injection volume
Output voltage
+25 %
±12.5 %
Injection volume
Output voltage
NG
+25 %
±12.5 %
Injection volume
Output voltage
NG
+25 %
±12.5 %
Injection volume
Output voltage
NG
+25 %
±12.5 %
Injection volume
Output voltage
NGExtremely rich or lean of the
actual air±fuel ratio
(Injector, fuel pressure, gas
leakage in exhaust system,
etc.) OK
OK
OK
No reaction
No reaction
No reaction No reaction

Sensor 2: rear sensor
(sensor 2, heater, sensor 2
circuit) 05±68
± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
HINT:
Hand±held tester only:
Narrowing down the trouble area is possible by performing ACTIVE TEST of the following ºA/F CONTROLº
(heated oxygen sensor or other trouble areas can be distinguished).
(a) Perform ACTIVE TEST using the hand±held tester (A/F CONTROL).
HINT:
ºA/F CONTROLº is an ACTIVE TEST which changes the injection volume ±12.5 % or +25 %.
(1) Connect the hand±held tester to the DLC3 on the vehicle.
(2) Turn the ignition switch ON.
(3) Warm up the engine with the engine speed at 2,500 rpm for approximately 90 sec.
(4) Select the item ºDIAGNOSIS / OBD/MOBD / ACTIVE TEST / A/F CONTROLº.
(5) Perform ºA/F CONTROLº with the engine in an idle condition (press the right or left button).
Result:
Heated oxygen sensor reacts in accordance with increase and decrease of injection volume:
+25 %
rich output: More than 0.55 V
±12.5 %
lean output: Less than 0.4 V
NOTICE:
There is a few second delay in the sensor 1 (front sensor) output, and there is about 20 seconds delay
in the sensor 2 (rear sensor) output.

05±60
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0133OXYGEN SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
CIRCUIT DESCRIPTION
Refer to DTC P0125 on page 05±45.
DTC NoDTC Detecting ConditionTrouble Area
P0133
Response time for heated oxygen sensor voltage output to
change from rich to lean, or from lean to rich, is 1.0 sec. or
more during idling after engine is warmed up (2 trip detection
logic)

Open or short in heated oxygen sensor circuit

Heated oxygen sensor

Air induction system

Fuel pressure

Injector

ECM
HINT:

 


 \f
\f















\b


\f

 
\f


 
 

\f
 \f
\f


WIRING DIAGRAM
Refer to DTC P0125 on page 05±45.
INSPECTION PROCEDURE
HINT:
Hand±held tester only:
Narrowing down the trouble area is possible by performing ACTIVE TEST of the following \
ºA/F CONTROLº
(heated oxygen sensor or other trouble areas can be distinguished).
(a) Perform ACTIVE TEST using hand±held tester (A/F CONTROL).
HINT:
ºA/F CONTROLº is an ACTIVE TEST which changes the injection volume\
±12.5 % or +25 %.
(1) Connect the hand±held tester to the DLC3 on the vehicle.
(2) Turn the ignition switch ON.
(3) Warm up the engine with the engine speed at 2,500 rpm for approximately. 90 sec.
(4) Select the item ºDIAGNOSIS / OBD/MOBD / ACTIVE TEST / A/F CONTROLº\
.
(5) Perform ºA/F CONTROLº with the engine in an idle condition (press\
the right or left button).
Result:
Heated oxygen sensor reacts in accordance with increase and decrease of injection volume:
+25 %
rich output: More than 0.55 V
±12.5 %
lean output: Less than 0.4 V
NOTICE:
There is a few second delay in the sensor 1 (front sensor) output, and ther\
e is about 20 seconds delay
in the sensor 2 (rear sensor) output.
05B3W±02

+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Case 1
Case 2
Case 3
Case 4
Output voltage of heated oxygen
sensor (sensor 1: front sensor)
Injection volume
Output voltage
Output voltage of heated oxygen
sensor (sensor 2: rear sensor)Mainly suspect
trouble area
OK
+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Injection volume
Output voltage
+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Injection volume
Output voltage
Sensor 1: front sensor
(sensor 1, heater, sensor 1
circuit)
+25 %
±12.5 %
More than 0.55 V
Less than 0.4V
Injection volume
Output voltage
+25 %
±12.5 %
Injection volume
Output voltage
NG
+25 %
±12.5 %
Injection volume
Output voltage
NG
+25 %
±12.5 %
Injection volume
Output voltage
NG
+25 %
±12.5 %
Injection volume
Output voltage
NGExtremely rich or lean of the
actual air±fuel ratio
(Injector, fuel pressure, gas
leakage in exhaust system,
etc.) OK
OK
OK
No reaction
No reaction
No reaction No reaction


Sensor 2: rear sensor
(sensor 2, heater, sensor 2
circuit)
± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±61
AVENSIS REPAIR MANUAL (RM1018E)
The following procedure of A/F CONTROL enable the technician to check and graph volatge output of the
heated oxygen sensor.
For displaying the graph indication, enter ºACTIVE TEST / A/F CONTROL / USER DATA,º then select ºO2S
B1S1 and O2S B1S2º by pressing ºYESº button and push ºENTERº button before pressing ºF4º button.
NOTICE:
If the vehicle is lack of fuel, the air±fuel ratio becomes LEAN and DTC P0133 will be set, and the CHK
ENG then comes on.
HINT:

If different DTCs that are related to a different system are output simultaneously while terminal E2 is
used as a ground terminal, terminal E2 may be open.

Read freeze frame data using    
 Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle
was running or stopped, the engine was warmed up or not, the air±fuel ratio was lean or rich, etc. at
the time of the malfunction.

A high heated oxygen sensor (sensor 1) voltage (0.55 V or more) could be caused by a rich air fuel
mixture. Check for conditions that would cause the engine to run rich.

A low heated oxygen sensor (sensor 1) voltage (0.4 V or less) could be caused by a lean air fuel mix-
ture. Check for conditions that would cause the engine to run lean.