2005 TOYOTA AVENSIS boot

010B2±13
N17080
Filler Cap
Float
Reservoir Tank

Grommet
Clip
Slotted Spring Pin
: Specified torque

Non±reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot

Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
± INTRODUCTIONHOW TO USE THIS MANUAL
01±1
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally, repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
3. Final Inspection
(c) This manual explains the 1st process of ºDiagnosisº (found in the ºDiagnosticsº section), the 2nd
pro-
cess of ºRemoving and Installing, Replacing, Disassembling, Installing and Checking, and Adjustingº,
but the 3rd process of ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the
item to be repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed under the title where necessary.
(b) Non±reusable parts, grease application area, precoated parts and tightening torque are specified in
the component drawings.
Example:

022KS±01
± PREPARATIONBRAKE
02±33
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE
PREPARATION
SST
09023±00100Union Nut Wrench 10 mmBRAKE FLUID
BRAKE MASTER CYLINDER
SUB±ASSY
FRONT BRAKE
REAR BRAKE
BRAKE BOOSTER ASSY(LHD)
BRAKE BOOSTER ASSY(RHD)
BRAKE ACTUATOR ASSY(W/ VSC)
BRAKE ACTUATOR ASSY(W/O VSC)
09023±38400Union Nut Wrench 14mmBRAKE FLUID
BRAKE MASTER CYLINDER
SUB±ASSY
FRONT BRAKE
REAR BRAKE
BRAKE BOOSTER ASSY(LHD)
BRAKE BOOSTER ASSY(RHD)
BRAKE ACTUATOR ASSY(W/ VSC)
09214±76011Crankshaft Pulley ReplacerSKID CONTROL SENSOR
09520±00031Rear Axle Shaft PullerSKID CONTROL SENSOR
(09520±00040)ShockerSKID CONTROL SENSOR
09521±00020Drive Shaft Boot Clamping ToolSKID CONTROL SENSOR
09550±60010Differential Side Bearing
ReplacerFRONT BRAKE
(09710±06051)ReplacerREAR BRAKE
09950±00020Bearing RemoverSKID CONTROL SENSOR
Recomended Tools
09042±00010Torx Socket T30STEERING SENSOR

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.

F40217
SSTTurn
Hold
C80293
D27403
C83023
± DRIVE SHAFT / PROPELLER SHAFTFRONT AXLE HUB SUB±ASSY LH
30±23
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE FRONT DISC
7. SEPARATE TIE ROD END SUB±ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, separate the tie rod end sub±assy LH from the
steering knuckle.
SST 09628±62011
8. SEPARATE FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and separate the suspension
arm sub±assy lower No.1 LH from the lower ball joint.
9. REMOVE FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the drive shaft assy LH
from the axle hub.
NOTICE:
Be careful not to damage the boot and ABS speed sensor
rotor.
(b) Remove the 2 bolts, nuts and steering knuckle with the
shock absorber.

C83023
C80293
30±26
±
DRIVE SHAFT / PROPELLER SHAFT FRONT AXLE HUB SUB±ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
19.INSTALL LOWER BALL JOINT ASSY FRONT LH
(a)Install the lower ball joint 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 up to 6\
0  further.
20.INSTALL FRONT AXLE ASSY LH
(a)Install the 2 bolts, nuts and steering knuckle with 2 bolts and nuts to the shock absorber.
Torque: 220 N
m (2,243 kgf
cm, 162 ft
lbf)
NOTICE:
Only when reusing the bolts and nuts, apply engine oil to
the screw part of the nuts.
(b)Push the front axle assy toward the outside of the vehicle, fit the splined part of the drive shaft assy to that of the front
axle assy and insert the drive shaft assy into the front axle
assy.
NOTICE:

Do not push out the front axle assy excessively.

Be careful not to damage the drive shaft outboard
joint boot.

Be careful not to damage the speed sensor rotor.
21.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a)Install the front suspension arm sub±assy lower No.1 LH and lower ball joint with the 2 nuts and bolt.
Torque: 89 N
m (908 kgf
cm, 66 ft
lbf)
22.INSTALL TIE ROD END SUB±ASSY LH
(a)Install the tie rod end sub±assy LH to the steering knuckle.
(b)Install the nut and a new cotter pin. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
NOTICE:
If the holes for the cotter pin are not aligned, tighten the nut up to 6\
0  further.
23.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
24. INSTALL FRONT DISC

F44775
F40217
SSTTurn
Hold
C80293
D27403
F40148SST
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±7
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the bolt, and disconnect the speed sensor from
the steering knuckle.
NOTICE:

Be careful not to damage the speed sensor.

Prevent foreign matter from attaching to the speed
sensor.
8. SEPARATE TIE ROD END SUB±ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, separate the tie rod end sub±assy LH from the
steering knuckle.
SST 09628±62011
9. SEPARATE FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and separate the front sus-
pension arm sub±assy lower No.1 LH from the lower ball
joint.
10. SEPARATE FRONT AXLE ASSY LH
(a) Using a plastic hammer, separate the front drive shaft
assy LH from the axle hub.
NOTICE:
Be careful not to damage the boot and speed sensor rotor.
11. REMOVE FRONT DRIVE SHAFT ASSY LH
(a) Using SST, remove the front drive shaft assy LH.
SST 09520±01010, 09520±24010 (09520±32040)
NOTICE:

Be careful not to damage the oil seal, boot and dust
cover.

Be careful not to drop the drive shaft assy.

C83155
1AZ±FSE/
1AZ±FE:
F44774
1CD±FTV:
F40218
SST
C91598
C86265
30±8
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE FRONT DRIVE SHAFT ASSY RH
HINT:
1AZ±FSE, 1AZ±FE, 1CD±FTV only
(a) Remove the 2 bolts and pull out the drive shaft together
with the center bearing bracket.
(b) Remove the drive shaft from the transaxle.
NOTICE:

Be careful not to damage the oil seal, boot and dust
cover.

Be careful not to drop the drive shaft assy.
13. FIX FRONT AXLE ASSY LH
NOTICE:
The hub bearing could be damaged if it is subjected to the
vehicle weight, such as when moving the vehicle with the
drive shaft removed.
Therefore, if it is absolutely necessary to place the vehicle
weight on the hub bearing, first support it with SST.
SST 09608±16042 (09608±02021, 09608±02041)
14. INSPECT FRONT DRIVE SHAFT ASSY LH
(a) Check that there is no remarkable play in the radial direc-
tion of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust
direction.
(c) Check that there is no remarkable play in the radial direc-
tion of the inboard joint.
(d) Check the boots for damage.
NOTICE:
Keep the drive shaft assy level during inspection.
15. REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) Using pliers, remove the inboard joint boot LH No.2
clamp, as shown in the illustration.
(b) Remove the inboard joint boot LH clamp by the same pro-
cedures as the inboard joint boot LH No.2 clamp.


F45461
Matchmarks
G24058
C91601
Matchmarks
F44759
± DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT
30±9
AVENSIS REPAIR MANUAL (RM1018E)
16. REMOVE FR AXLE INBOARD JOINT BOOT
(a) Remove the inboard joint boot from the inboard joint assy LH.
17. REMOVE FRONT DRIVE INBOARD JOINT ASSY LH
(a) Remove the old grease from the inboard joint.
(b) Place matchmarks on the inboard joint assy LH and out-
board joint shaft assy LH.
NOTICE:
Do not punch the marks.
(c) Remove the inboard joint assy LH from the outboard joint
shaft assy LH.
(d) Using a snap ring expander, remove the shaft snap ring.
(e) Place matchmarks on the outboard joint shaft assy LH
and tripod joint assy.
NOTICE:
Do not punch the marks.
(f) Using a brass bar and hammer, remove the tripod joint
assy from the outboard joint shaft assy LH.
NOTICE:
Do not tap the roller.
(g) Remove the inboard joint boot and 2 clamps.
18. REMOVE DAMPER, DRIVE SHAFT
HINT:

Except 1AZ±FSE, FE (MT)/ 1CD±FTV

Perform the procedure only when reassembling the RH
side.
(a) Using pliers, remove the damper clamp, as shown in the
illustration.
(b) Remove the drive shaft damper.