2005 TOYOTA AVENSIS suspension

C80880
F13686
26±14
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
(d) Install the flexible hose and ABS speed sensor wire har- ness bracket with the bolt.
Torque: 19 N
m (192 kgf
cm, 14 ft
lbf)
25. INSTALL 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.
26. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
27.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)

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.

SA0028
AB
FrontA B
A: Inside
B: Outside
Z03382
Alignment
TesterGauge
± FRONT SUSPENSIONFRONT WHEEL ALIGNMENT
26±7
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully and measure the turning
angle.
Wheel turning angle:
(Normal package)
Inside wheel
17'  2 

  

47'  2 

  
Outside wheel: Reference3252'  

315'  

(Rough road package)
Inside wheel
42'  2 
  
09'  2  
  
Outside wheel: Reference3316'  
3138'   
*1: Electric motor power steering models
*2: 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. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Install the camber±caster±kingpin 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
Right±left error±034'  45' (±0.57  0.75)
45' (0.75) or less
Caster
Right±left error54'  45' (2.90  0.75)
45' (0.75) or less
Steering axis inclination
Right±left error27'  45' (12.45  0.75)
45' (0.75) or less
(Rough road package)
Camber
Right±left error±019'  45' (±0.32  0.75)
45' (0.75) or less
Caster
Right±left error40'  45' (2.67  0.75)
45' (0.75) or less
Steering axis inclination
Right±left error56'  45' (11.93  0.75)
45' (0.75) or less
If the caster and steering axis inclination are not within the spe-
cified values, after the camber has been correctly adjusted, re-
check the suspension parts for damaged and/or worn out parts.

F13683
26±8
± FRONT SUSPENSIONFRONT WHEEL ALIGNMENT
AVENSIS REPAIR MANUAL (RM1018E)
7. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe±in.
(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 en-
gine oil.
(c) Clean the installation surfaces of the shock absorber and
the steering knuckle.
(d) Temporarily install the 2 bolts and nuts.

F44962
+
±
F13685
1
2
F12938
Bolt
Adjusting
ValueSet BoltAdjusting Bolt90105±17008 90105±17009
90105±17010 90105±17011
121212121 Dot
2 Dots3 Dots
±130' ± ±115'
±115' ± ±100'
±100' ± ±45'
±45' ± ±30'
±30' ± ±15'
0' ± 15'
15' ± 30'
30' ± 45'
45' ± 1

100' ± 115' ±15' ± 0'
115' ± 130'
± FRONT SUSPENSIONFRONT 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.

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

30091±02

D30592
Speed Sensor Front LH
Lower Ball Joint
Assy Front LH
N
m (kgf
cm, ft
lbf): Specified torque
8.0 (82, 71 in.
lbf)
49 (500, 36)
Tie Rod End Sub±assy LH
Cotter Pin
Front Disc
Front Axle Assy LH
19 (194, 14)
Front Stabilizer Link Assy LH
74 (755, 55)
220 (2,243, 162)
Front Drive Shaft
Assy LH
Front Axle Hub LH Nut
216 (2,200, 159)

Front Axle
LH Hub Bolt
89 (908, 66)
Steering Knuckle LH
Disc Brake Dust Cover Front LH
8.3 (85, 73 in.
lbf)
8.3 (85, 73 in.
lbf)Front Axle
Hub Sub±assy LH
Front Disc Brake
Caliper Assy LH
Front Suspension Arm
Sub±assy Lower No. 1 LH

Front Axle Hub
LH Bearing

Cotter Pin
103 (1,050, 76)
102 (1,040, 75)

Non±reusable parts
Front Axle Hub
LH Snap Ring
± DRIVE SHAFT / PROPELLER SHAFTFRONT AXLE HUB SUB±ASSY LH
30±21
AVENSIS REPAIR MANUAL (RM1018E)
FRONT AXLE HUB SUB±ASSY LH
COMPONENTS