2610

FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING

FRONT SHOCK ABSORBER WITH COIL SPRING

2600M04

OVERHAUL
HINT:
S S

1.

COMPONENTS: See page 262 This procedure is provided for the overhaul on the LH side. Overhaul the other side by the same procedure as the LH side. REMOVE FRONT WHEEL

2. (a)

SEPARATE FRONT STABILIZER LINK ASSY LH Remove the nut and disconnect the stabilizer bar link from the shock absorber.

HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

F13686

3. (a)

REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING Remove the bolt, disconnect the front flexible hose and speed sensor front LH.

C80880

(b)

Remove the 2 nuts and bolts on the lower side of the shock absorber.

F13683

(c) (d)

Remove the 3 nuts on the upper side of the shock absorber. Remove the shock absorber with the coil spring.

F44622

AVENSIS REPAIR MANUAL (RM1018E)

2611
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING

4. (a)

FIX FRONT SHOCK ABSORBER WITH COIL SPRING Install 2 nuts and a bolt to the bracket at the lower side of the shock absorber and secure it in a vise.

28mm

F44963

5.

REMOVE FRONT SUSPENSION SUPPORT DUST COVER LH

6.

SST

REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER LH NUT (a) Using SST, compress the coil spring. SST 0972730021 NOTICE: Do not use an impact wrench. It will damage the SST. (b) Remove the front suspension support dust cover from the suspension support.
F40270

(c)

Using SST to hold the spring seat, remove the nut. SST 0972922031

SST

F08624

7. 8. 9. 10. 11. 12. 13.

REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE

FRONT SUSPENSION SUPPORT SUBASSY LH FRONT SUSPENSION SUPPORT LH DUST SEAL FRONT COIL SPRING SEAT UPPER LH FRONT COIL SPRING INSULATOR UPPER LH FRONT COIL SPRING LH FRONT SPRING BUMPER LH FRONT COIL SPRING INSULATOR LOWER LH

AVENSIS REPAIR MANUAL (RM1018E)

2612
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING

14. (a)

C80884

INSPECT SHOCK ABSORBER ASSY FRONT LH Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL on page 2615.

15. INSTALL FRONT COIL SPRING INSULATOR LOWER LH HINT: Fit the front coil spring insulator lower into the gap of the shock absorber. (a) Install the front coil spring insulator lower onto the shock absorber. 16. INSTALL FRONT SPRING BUMPER LH (a) Install the spring bumper to the piston rod.

SST

17. (a)

F40271

INSTALL FRONT COIL SPRING LH Using SST, compress the coil spring. SST 0972730021 NOTICE: Do not use an impact wrench. It will damage the SST. (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the front coil spring insulator lower LH. 18. INSTALL FRONT COIL SPRING INSULATOR UPPER LH Install the upper insulator as shown in the illustration.

Outside Outside

(a)

F13692

Outside

19. (a)

INSTALL FRONT COIL SPRING SEAT UPPER LH Install the spring seat to the shock absorber with the mark facing to the outside of the vehicle.

F40272

AVENSIS REPAIR MANUAL (RM1018E)

2613
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING

20. (a) 21.

INSTALL FRONT SUSPENSION SUPPORT LH DUST SEAL Install a new dust seal. INSTALL FRONT SUSPENSION SUPPORT SUBASSY LH

22. (a)

SST SST
F08624

(b)

INSTALL FRONT SUPPORT TO FRONT SHOCK ABSORBER LH NUT Using SST to hold the suspension support, install a new nut. SST 0972922031 Torque: 47 NVm (479 kgfVcm, 35 ftVlbf) Remove the SST. SST 0972730021,0972922031

MP Grease No. 2

23.

INSTALL FRONT SUSPENSION SUPPORT DUST COVER LH (a) Apply MP grease No. 2 into the suspension support. CAUTION: Do not touch grease on rubber surface of the suspension support. (b) Install the dust cover.
F40273

24. (a) (b)

INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING Install the shock absorber with the 2 bolts. Install the 3 nuts on the upper side of shock absorber. Torque: 39 NVm (398 kgfVcm, 29 ftVlbf)

F44622

(c)

Install the 2 nuts to the lower side of shock absorber. Torque: 220 NVm (2,240 kgfVcm, 162 ftVlbf)

HINT: Coat the threads of the nuts with engine oil.

F13683

AVENSIS REPAIR MANUAL (RM1018E)

2614
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING

(d)

Install the flexible hose and ABS speed sensor wire harness bracket with the bolt. Torque: 19 NVm (192 kgfVcm, 14 ftVlbf)

C80880

25. (a)

INSTALL FRONT STABILIZER LINK ASSY LH Install the stabilizer bar link with the nut. Torque: 74 NVm (755 kgfVcm, 55 ftVlbf)

HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

F13686

26. 27.

INSTALL FRONT WHEEL Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 266)

AVENSIS REPAIR MANUAL (RM1018E)

2615
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
2600N04

DISPOSAL
HINT: Dispose the RH side by the same procedures as the LH side.

DISPOSE OF SHOCK ABSORBER ASSY FRONT LH Fully extend the shock absorber rod. Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION: S When drilling, chips may fly out. Work carefully. S The gas is colorless, odorless and nonpoisonous.
G22948 F45774

1. (a) (b)

AVENSIS REPAIR MANUAL (RM1018E)

262
FRONT SUSPENSION FRONT SUSPENSION

FRONT SUSPENSION
260DP01

COMPONENTS
39 (398, 29)

Front Shock Absorber with Coil Spring

Front Stabilizer Link Assy LH

74 (755, 55) 19 (194, 14)

Front Suspension Support Dust Cover LH

47 (479, 35)

Front Suspension Support Subassy LH Front Suspension Support LH Dust Seal

220 (2,240, 162)

Speed Sensor Front LH Front Flexible Hose

Front Spring Bumper LH Front Coil Spring Seat Upper LH

Front Axle Assy

Front Coil Spring Insulator Lower LH

Front Coil Spring Insulator Upper LH Shock Absorber Assy Front LH Front Coil Spring LH

NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part

F44614

AVENSIS REPAIR MANUAL (RM1018E)

263
FRONT SUSPENSION FRONT SUSPENSION

49 (500, 36)

Rack & Pinion Power Steering Gear Assy

Engine Mounting Member Subassy Center

Tie Rod End Subassy LH Transverse Engine Engine Mounting Insulator

Front Stabilizer Link Assy RH

Front Stabilizer Link Assy LH Front Suspension Crossmember Subassy Front Suspension Member Body Mounting Stopper FR
133 (1,360, 98)

133 (1,360, 98)

Front Suspension Member Brace Rear RH

80 (816, 59)

137 (1,400, 101)

137 (1,400, 101)

Body Mounting Stopper Rear

80 (816, 59) 133 (1,360, 98) 96 (979, 71) 80 (816, 59) 74 (755, 55) 52 (530, 38)

Front Suspension Member Brace Rear LH

80 (816, 59) 133 (1,360, 98)

zCotter Pin
49 (500, 36)

Front Suspension Arm Subassy Lower No.1 LH

89 (908, 66)

NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part zN bl t

AVENSIS REPAIR MANUAL (RM1018E)
F44615

264
FRONT SUSPENSION FRONT SUSPENSION

Front Shock Absorber with Coil Spring

220 (2,240, 162)

Front Drive Shaft Assy LH

Speed Sensor Front LH

8 (82, 71 in.Vlbf)

z Cotter Pin
49 (500, 36) 102 (1,040, 75)

Tie Rod End Subassy LH

z Cotter Pin Front Disc Brake Caliper Assy LH

103 (1,050, 76)

Front Disc

Front Suspension Arm Subassy Lower No.1 LH

Front Axle Assy LH Lower Ball Joint Assy Front LH

216 (2,200, 159)

Front Axle Hub LH Nut

89 (908, 66)

NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part

F44616

AVENSIS REPAIR MANUAL (RM1018E)

265
FRONT SUSPENSION FRONT SUSPENSION

w/ HID:

49 (500, 36) 5.4 (55, 48 in.Vlbf) 49 (500, 36)

19 (194, 14)

Rack & Pinion Power Steering Gear Assy HID Height Control Sensor
19 (194, 14) 19 (194, 14)

Tie Rod End Subassy LH

Front Stabilizer Bracket No.1 RH Front Stabilizer Link Assy RH

Front Stabilizer Bracket No.1 LH Front Stabilizer Link Assy LH

74 (755, 55)

Stabilizer Bar Front Front Suspension Arm Subassy Lower No.1 RH Front Stabilizer Bar Bush No.1
74 (755, 55)

133 (1,360, 98)

Front Suspension Crossmember Subassy Front Suspension Arm Subassy Lower No.1 LH Body Mounting Stopper Rear
89 (908, 66)

Front Suspension Member Brace Rear RH

96 (979, 71)

80 (816, 59)

133 (1,360, 98) 80 (816, 59)

52 (530, 38)

133 (1,360, 98) 80 (816, 59)

Front Suspension Member Body Mounting Stopper FR Front Suspension Member Brace Rear LH

80 (816, 59) 133 (1,360, 98) 80 (816, 59) 74 (755, 55)

z Cotter Pin
49 (500, 36)

NVm (kgfVcm, ftVlbf) : Specified torque z Nonreusable part

AVENSIS REPAIR MANUAL (RM1018E)
F45154

2616

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (ATM)

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (ATM)

260DQ01

REPLACEMENT
HINT:
S S S

1.

COMPONENTS: See page 262 Replace the RH side (Engine: 1AZ) by the same procedures as the LH (ATM) side. Replace the RH side (Engine: 1ZZ) by the same procedures as the LH (MTM) side. REMOVE FRONT WHEELS 2. (a) SEPARATE FRONT STABILIZER LINK ASSY LH Remove the nut and disconnect the stabilizer bar link from the shock absorber.

HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

F13686

3. SEPARATE FRONT STABILIZER LINK ASSY RH HINT: Separate the RH side by the same procedures as the LH side. 4. SEPARATE TIE ROD END SUBASSY LH (See page 306) SST 0962862011 5. SEPARATE TIE ROD END SUBASSY RH SST 0962862011 HINT: Separate the RH side by the same procedures as the LH side. 6. (a) SEPARATE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Remove the bolt and 2 nuts, and separate the front suspension arm subassy lower No.1 from the lower ball joint.

C80293

7. SEPARATE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 RH HINT: Separate the RH side by the same procedures as the LH side. 8. SEPARATE RACK & PINION POWER STEERING GEAR ASSY (a) Electric power steering model: See page 5128 (b) Oil pressure power steering model: See page 5136 9. SUSPEND ENGINE ASSY (a) U341E: See page 4011 (b) U241E: See page 4025
AVENSIS REPAIR MANUAL (RM1018E)

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (ATM)

2617

10. (a) (b) (c)

C95317

REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH Support the front suspension crossmember subassy with a transmission jack. Remove the 4 bolts and front suspension member brace rear LH. Remove the front suspension member body mounting stopper rear from the front suspension member brace rear LH.

11. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH HINT: Remove the RH side by the same procedures as the LH side.

12. (a) (b)

SEPARATE FRONT SUSPENSION CROSSMEMBER SUBASSY w/ HID: Disconnect the height control sensor (Front) connector. Remove the 3 bolts and 3 nuts, disconnect the transverse engine engine mounting insulator and engine mounting member subassy center from the front suspension crossmember subassy.

C86742

(c) (d)

Remove the 2 nuts and 2 front suspension member body mounting stoppers front. Lower the transmission jack, remove the front suspension crossmember subassy.

C87504

13. (a)

REMOVE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Remove the 2 bolts, nut and lower suspension arm sub assy lower No.1 LH from the front suspension crossmember subassy.

C95318

AVENSIS REPAIR MANUAL (RM1018E)

2618

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (ATM)

14. (a)

TEMPORARILY TIGHTEN FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Install the lower suspension arm subassy lower No.1 LH, and temporarily tighten the 2 bolts and nut.

C95318

15. (a) (b)

INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSY Support the front suspension crossmember subassy with a transmission jack. Install the 2 front suspension member body mounting stoppers front and 2 nuts. Torque: 133 NVm (1,360 kgfVcm, 98 ftVlbf)

C87504

(c)
A A

(d)

B A A B
C86742

(e)

Connect the transverse engine engine mounting insulator and engine mounting member subassy center to the front suspension crossmember subassy. Install the 3 bolts and 3 nuts. Torque: Bolt A: 52 NVm (530 kgfVcm, 38 ftVlbf) Bolt B: 96 NVm (979 kgfVcm, 71 ftVlbf) w/ HID: Connect the height control sensor (Front) connector. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH Install the front suspension member body mounting stopper rear to the front suspension member brace rear LH. Install the 4 bolts and front suspension member brace rear LH. Torque: Bolt A: 80 NVm (816 kgfVcm, 59 ftVlbf) Bolt B: 133 NVm (1,360 kgfVcm, 98 ftVlbf)

16. (a)
B A A A

(b)

C95317

17. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH HINT: Install the RH side by the same procedures as the LH side. 18. CONNECT RACK & PINION POWER STEERING GEAR ASSY (a) Electric power steering model: See page 5128 (b) Oil pressure power steering model: See page 5136

AVENSIS REPAIR MANUAL (RM1018E)

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (ATM)

2619

19. (a)

CONNECT FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Connect the lower suspension arm to the lower ball joint with the 2 nuts and bolt. Torque: 89 NVm (908 kgfVcm, 66 ftVlbf)

C80293

20. CONNECT FRONT SUSPENSION ARM SUBASSY LOWER NO.1 RH HINT: Connect the RH side by the same procedures as the LH side. 21. INSTALL TIE ROD END SUBASSY LH (See page 306) 22. INSTALL TIE ROD END SUBASSY RH HINT: Connect the RH side by the same procedures as the LH side.

23. (a)

CONNECT FRONT STABILIZER LINK ASSY LH Install the stabilizer bar link with the nut. Torque: 74 NVm (755 kgfVcm, 55 ftVlbf)

HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

F13686

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 NVm (1,050 kgfVcm, 76 ftVlbf) (b) Bounce the vehicle up and down several times to stabilize the suspension.

26. (a)

FULLY TIGHTEN FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Fully tighten the 2 bolts and nut. Torque: 137 NVm (1,400 kgfVcm, 101 ftVlbf)

C80889

AVENSIS REPAIR MANUAL (RM1018E)

2620

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (ATM)

27.

INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 266)

AVENSIS REPAIR MANUAL (RM1018E)

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (MTM)

2621

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (MTM)

260DR01

REPLACEMENT
HINT:
S S S

1.

COMPONENTS: See page 262 Replace the RH side (Engine: 1AZ) by the same procedures as the LH (ATM) side. Replace the RH side (Engine: 1ZZ, 3ZZ, 1CD) by the same procedures as the LH (MTM) side. REMOVE FRONT WHEELS 2. (a) SEPARATE FRONT STABILIZER LINK ASSY LH Remove the nut and disconnect the stabilizer bar link from the shock absorber.

HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

F13686

3. SEPARATE FRONT STABILIZER LINK ASSY RH HINT: Separate the RH side by the same procedures as the LH side.

4. (a)

SEPARATE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Remove the bolt and 2 nuts, and separate the lower suspension arm from the lower ball joint.

F41742

5. (a)

REMOVE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Remove the 2 bolts, nut and lower suspension arm sub assy lower No.1 LH from the front suspension crossmember subassy.

C80889

AVENSIS REPAIR MANUAL (RM1018E)

2622

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (MTM)

6. (a)

TEMPORARILY TIGHTEN FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Install the lower suspension arm, temporary tighten the 2 bolts and nut.

C80889

7. (a)

CONNECT FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Connect the lower suspension arm to the lower ball joint with the 2 nuts and bolt. Torque: 89 NVm (908 kgfVcm, 66 ftVlbf)

F41742

8. (a)

CONNECT FRONT STABILIZER LINK ASSY LH Install the stabilizer bar link with the nut. Torque: 74 NVm (755 kgfVcm, 55 ftVlbf)

HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

F13686

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 NVm (1,050 kgfVcm, 76 ftVlbf) (b) Bounce the vehicle up and down several times to stabilize the suspension.

11. (a)

FULLY TIGHTEN FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH Fully tighten the 2 bolts and nut. Torque: 137 NVm (1,400 kgfVcm, 101 ftVlbf)

C80889

AVENSIS REPAIR MANUAL (RM1018E)

FRONT SUSPENSION

FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (MTM)

2623

12.

INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 266)

AVENSIS REPAIR MANUAL (RM1018E)

261
FRONT SUSPENSION FRONT SUSPENSION SYSTEM

FRONT SUSPENSION SYSTEM

2600K06

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.
Symptom 4. 5. 6. 7. 8. Suspect Area Tire (Worn or improperly inflated) Wheel alignment (Incorrect) Steering linkage (Loose or worn) Hub bearing (Worn) Steering gear (Out of adjustment or broken) See page 281 266 302 5128 5136 2610 2610 281 2626 2610 281 281 2610 266 2624 302 5128 5136 281 266 2610

Wander/pulls

9. Suspension parts (Worn) Bottoming 1. Vehicle (Overloaded) 2. Spring (Weak) 3. Shock absorber (Worn) 1. Tire (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) 3. Shock absorber (Worn) 1. 2. 3. 4. 5. 6. 7. 8. 1. 2. 3. 4. Tire (Worn or improperly inflated) Wheel (Out of balance) Shock absorber (Worn) Wheel alignment (Incorrect) Ball joint (Worn) Hub bearing (Worn) Steering linkage (Loose or worn) Steering gear (Out of adjustment or broken) Tire (Worn or improperly inflated) Wheel alignment (Incorrect) Shock absorber (Worn) Suspension parts (Worn)

Sways/pitches

Front wheel shimmy

Abnormal tire wear

AVENSIS REPAIR MANUAL (RM1018E)

266
FRONT SUSPENSION FRONT WHEEL ALIGNMENT

FRONT WHEEL ALIGNMENT

2600L02

ADJUSTMENT
1. INSPECT TIRE (See page 281)
Front:

2. MEASURE VEHICLE HEIGHT Vehicle height: (Normal package)

Front Rear A B: 92 mm (3.62 in.) D C: 61 mm (2.40 in.)

(Rough road package)

A
Front A B: 72 mm (2.83 in.) D C: 41 mm (1.61 in.)

B
F44617

Rear

Rear:

D C
F44618

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 pushing down or lifting the body. 3. INSPECT TOEIN Toein:
Toein (total) A + B: 006 12 (0.1 0.2) C D: 1 2 mm (0.04 0.08 in.)

B D Front

C
SA3213

If the toein is not within the specified value, adjust it at the rack ends. 4. ADJUST TOEIN (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 toein. HINT: Adjust the toein to the center of the specified value as much as possible. (d) (e) Make sure that the lengths of the right and left rack ends are the same. Torque the tie rod end lock nuts. Torque: 74 Nm (755 kgfcm, 55 ftlbf) Place the boots on the seats and install the clips.

(f) HINT: Make sure that the boots are not twisted.
F44619

AVENSIS REPAIR MANUAL (RM1018E)

267
FRONT SUSPENSION FRONT WHEEL ALIGNMENT

B Front

5. (a)

INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle. Wheel turning angle: (Normal package)
Inside wheel 3817 2 (38.28 2) *1 3547 2 (35.78 2) *2 3252 (32.87) *1 3115 (31.25) *2

A: Inside B: Outside
SA0028

Outside wheel: Reference

(Rough road package)

Inside wheel Outside wheel: Reference 3842 2 (38.70 2) *1 3609 2 (36.15 2) *2 3316 (33.27) *1 3138 (31.63) *2

*1: *2:

Electric motor power steering models Oil pressure power steering models If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths.

6.
Gauge Alignment Tester

INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Install the cambercasterkingpin gauge or position the vehicle on the wheel alignment tester. (b) Inspect the camber, caster and steering axis inclination. Camber, caster and steering axis inclination: (Normal package)
Camber
Z03382

Rightleft error Caster Rightleft error Steering axis inclination Rightleft error

034 45 (0.57 0.75) 45 (0.75) or less 254 45 (2.90 0.75) 45 (0.75) or less 1227 45 (12.45 0.75) 45 (0.75) or less

(Rough road package)

Camber Rightleft error Caster Rightleft error Steering axis inclination Rightleft error 019 45 (0.32 0.75) 45 (0.75) or less 240 45 (2.67 0.75) 45 (0.75) or less 1156 45 (11.93 0.75) 45 (0.75) or less

If the caster and steering axis inclination are not within the specified values, after the camber has been correctly adjusted, recheck the suspension parts for damaged and/or worn out parts.

AVENSIS REPAIR MANUAL (RM1018E)

268
FRONT SUSPENSION FRONT WHEEL ALIGNMENT

7. ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toein. (a) Remove the front wheel. (b) Remove the 2 bolts and nuts on the lower side of the shock absorber. If reusing the bolts and/or nuts, coat the threads of nuts with engine oil. (c) Clean the installation surfaces of the shock absorber and the steering knuckle. (d) Temporarily install the 2 bolts and nuts.
F13683

AVENSIS REPAIR MANUAL (RM1018E)

269
FRONT SUSPENSION FRONT WHEEL ALIGNMENT

(e)

(f) (g) (h)

F44962

Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. Tighten the nuts. Torque: 220 NVm (2,240 kgfVcm, 162 ftVlbf) Install the front wheel. Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) Check the camber.

HINT:
1

2
F13685

Adjust the camber to the center of the specified value as much as possible. S Adjusting value for the set bolts is 6 30 (0.1 0.5). If the camber is not within the specified value, using the following 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.

Set Bolt Bolt

Adjusting Bolt

9010517008 9010517009 9010517010 901051701 1

1 Dot

2 Dots

3 Dots

Adjusting Value
130 115 115 100 100 45 45 30 30 15 15 0 0 15 15 30 30 45 45 100' 100 115 115 130

F12938

(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.
AVENSIS REPAIR MANUAL (RM1018E)

2624
FRONT SUSPENSION LOWER BALL JOINT ASSY FRONT LH

LOWER BALL JOINT ASSY FRONT LH

260DS01

REPLACEMENT
HINT:
S S

COMPONENTS: See page 262 Replace the RH side by the same procedures as the LH side.

1. (a) (b)

INSPECT LOWER BALL JOINT ASSY FRONT LH Jack up front side of the vehicle. Check that there is no looseness on the ball joint by shaking the lower arm up and down with a force of 294 N (30 kgf, 66 lbf).

G22708

2. 3. 4. 5. 6. 7. 8. 9.

REMOVE FRONT WHEEL SEPARATE FRONT AXLE HUB LH NUT (See page 306) SST 0993000010 DISCONNECT SPEED SENSOR FRONT LH (See page 306) SEPARATE FRONT DISC BRAKE CALIPER ASSY LH (See page 3022) REMOVE FRONT DISC SEPARATE TIE ROD END SUBASSY LH (See page 3022) SST 0962862011 SEPARATE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (See page 3022) REMOVE FRONT AXLE ASSY LH (See page 3022) 10. REMOVE LOWER BALL JOINT ASSY FRONT LH SST (a) Remove the cotter pin and nut. (b) Using SST, remove the lower ball joint assy front LH.

F40228

11. (a) (b)

INSPECT LOWER BALL JOINT ASSY FRONT LH As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. 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 Nm (10 50 kgfcm, 9 43 in.lbf)

ZX1712

AVENSIS REPAIR MANUAL (RM1018E)

2625
FRONT SUSPENSION LOWER BALL JOINT ASSY FRONT LH

INSTALL LOWER BALL JOINT ASSY FRONT LH Install the lower ball joint assy front LH, and torque the nut. Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) (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 3022) 14. INSTALL FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (See page 3022) 15. INSTALL TIE ROD END SUBASSY LH (See page 3022) 16. INSTALL FRONT DISC 17. INSTALL FRONT DISC BRAKE CALIPER ASSY LH (See page 3022) 18. CONNECT SPEED SENSOR FRONT LH (See page 306) 19. INSTALL FRONT AXLE HUB LH NUT (See page 306) 20. INSTALL FRONT WHEEL Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) 21. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 266) 22. CHECK ABS SPEED SENSOR SIGNAL (a) w/o VSC: See page 05699 (b) w/ VSC: See page 05756

12. (a)

AVENSIS REPAIR MANUAL (RM1018E)

2626
FRONT SUSPENSION STABILIZER BAR FRONT

STABILIZER BAR FRONT

2600P03

REPLACEMENT
HINT: COMPONENTS: See page 262 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.

F44620

3. REMOVE FRONT STABILIZER LINK ASSY RH HINT: Remove the RH side by the same procedures as the LH side.

4. (a) (b)

INSPECT FRONT STABILIZER LINK ASSY LH As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. 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 Nm (0.5 20 kgfcm, 0.4 17 in.lbf)

G21679

5. 6.

SEPARATE TIE ROD END SUBASSY LH (See page 306) SST 0962862011 SEPARATE TIE ROD END SUBASSY RH SST 0962862011

HINT: Separate the RH side by the same procedures as the LH side. 7. SEPARATE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (See page 306) 8. SEPARATE FRONT SUSPENSION ARM SUBASSY 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 5128 (b) Oil pressure power steering model: See page 5136

AVENSIS REPAIR MANUAL (RM1018E)

2627
FRONT SUSPENSION STABILIZER BAR FRONT

10. SUSPEND ENGINE ASSY (a) 1ZZ, 3ZZ Engine: See page 4115 (b) 1AZ Engine: See page 4124 (c) 1CD Engine: See page 4133 11. REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH (See page 2616) 12. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH HINT: Remove the RH side by the same procedures as the LH side. 13. SEPARATE FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2616) 14. REMOVE FRONT STABILIZER BRACKET NO.1 LH (a) Remove the 2 bolts and the front stabilizer bracket No.1 LH.

15. (a)

(b)

REMOVE FRONT STABILIZER BRACKET NO.1 RH w/ HID: Remove the 3 bolts, the front stabilizer bracket No.1 RH and the height control sensor (Front). w/o HID: Remove the 2 bolts and the front stabilizer bracket No.1 RH.

F45155

16. (a) 17. 18.

REMOVE FRONT STABILIZER BAR BUSH NO.1 Remove the 2 bushings from the stabilizer bar. REMOVE STABILIZER BAR FRONT INSTALL STABILIZER BAR FRONT 19. (a) INSTALL FRONT STABILIZER BAR BUSH NO.1 Install the 2 front stabilizer bar bush No.1 to the stabilizer bar front as shown in the illustration.

Inner Side

Rear Side
C81547 F40197

HINT: Install the bushing to the outer side of the bushing stopper on the stabilizer bar.

20. (a)

INSTALL FRONT STABILIZER BRACKET NO.1 LH Install the front stabilizer bracket No.1 LH with the 2 bolts. Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)

AVENSIS REPAIR MANUAL (RM1018E)

2628
FRONT SUSPENSION STABILIZER BAR FRONT

22. 23. 24. 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 5128 (b) Oil pressure power steering model: See page 5136 26. INSTALL FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (See page 306) 27. INSTALL FRONT SUSPENSION ARM SUBASSY LOWER NO.1 RH HINT: Connect the RH side by the same procedures as the LH side. 28. INSTALL TIE ROD END SUBASSY LH (See page 306) 29. INSTALL TIE ROD END SUBASSY RH HINT: Connect the RH side by the same procedures as the LH side.

INSTALL FRONT STABILIZER BRACKET NO.1 RH 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 NVm (55 kgfVcm, 48 in.Vlbf) Bolt B: 19 NVm (194 kgfVcm, 14 ftVlbf) (b) w/o HID: B Install the front stabilizer bracket No.1 RH with the 2 bolts. F45155 Torque: 19 NVm (194 kgfVcm, 14 ftVlbf) INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2616) INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH (See page 2616) INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
A

21. (a)

30. (a)

INSTALL FRONT STABILIZER LINK ASSY LH Install the front stabilizer link assy LH with the 2 nuts. Torque: 74 NVm (755 kgfVcm, 55 ftVlbf)

HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

F44620

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 NVm (1,050 kgfVcm, 76 ftVlbf) 33. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 266) 34. HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 6519)

AVENSIS REPAIR MANUAL (RM1018E)