Page 4729 of 5135
F45361F46832
C80802
F46213
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
C80806
32−6
−
BRAKE BRAKE BOOSTER ASSY (RHD) (2AZ −FSE)
AVENSIS Supplement (RM1045E)
(b) Using SST, connect the 3 brake tubes to the ways. SST 09023 −00100
Torque: 15N m( 155 kgf cm, 11 ft lbf)
(c) Using SST and a spanner, connect the brake tube to the flexible hose of front brake RH.
SST 09023 −00100
Torque: 15N m( 155 kgf cm, 11 ft lbf)
(d) Using SST, connect the 6 brake tubes to the brake actua- tor, as shown in the illustration.
SST 09023 −00100
Torque: 15N m( 155 kgf cm, 11 ft lbf)
(e) Install the brake tube clamps with the 2 bolts. Torque: 6.0 N m(6 1 kgf cm, 53 in. lbf)
1 6. INSTALL BRAKE MASTER CYLINDER SUB −ASSY
SST 09023 −00100
1 7. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14− 23)
1 8. INSTALL IGNITION COIL ASSY (SEE PAGE 14− 79)
1 9. INSTALL CYLINDER HEAD COVER SUB −ASSY (SEE PAGE 14− 79)
Page 4730 of 5135
− BRAKEBRAKE BOOSTER ASSY (RHD) (2AZ−FSE)
32−7
AVENSIS Supplement (RM1045E)
20. INSTALL ENGINE COVER NO.1
21. INSTALL FRONT WHEEL RH
Torque:103 Nm(1,050 kgfcm, 76 ftlbf)
22. FILL RESERVOIR WITH BRAKE FLUID
23. BLEED MASTER CYLINDER
SST 09023−00100
24. BLEED BRAKE LINE
25. CHECK AND ADJUST BRAKE PEDAL HEIGHT
26. CHECK PEDAL FREE PLAY
27. CHECK PEDAL RESERVE DISTANCE
28. CHECK FLUID LEVEL IN RESERVOIR
29. CHECK BRAKE FLUID LEAKAGE
Page 4731 of 5135
300N6−01
C53220F45751
SST
F13686
Hold
Turn
C80291
F44775
30−4
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
AVENSIS Supplement (RM1045E)
OVERHAUL
HINT:
Overhaul the RH side following the same procedure as for the LH side.
1. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
(a) Remove the drain plug and gasket, and then drain the ATF.
(b) Install a new gasket and drain plug.
Torque: 49 Nm (500 kgfcm, 36 ftlbf)
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER LH
4. SEPARATE FRONT AXLE HUB LH NUT
(a) Using SST and a hammer, unstake the staked part of the
nut.
SST 09930−00010
(b) While applying the brake, remove the axle hub LH nut.
NOTICE:
Loosen the staked part of the lock nut completely, other-
wise the screw of the drive shaft may become damaged.
5. SEPARATE FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and separate the front stabilizer link assy
LH from the shock absorber assy LH.
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
6. DISCONNECT SPEED SENSOR FRONT LH
(a) Remove the bolt, and disconnect the speed sensor wire
and flexible hose from the shock absorber.
(b) Remove the bolt, and disconnect the speed sensor from
the steering knuckle.
NOTICE:
SBe careful not to damage the speed sensor.
SPrevent foreign matter from adhering to the speed
sensor.
Page 4732 of 5135
F40217
SSTTurn
Hold
C80293
D27403
F40148SST
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
30−5
AVENSIS Supplement (RM1045E)
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.1LH
(a) Remove the bolt and 2 nuts, and separate the front sus-
pension arm sub−assy lower No.1LH from the lower ball
joint.
9. 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.
10. REMOVE FRONT DRIVE SHAFT ASSY LH
(a) Using SST, remove the front drive shaft assy LH.
SST 09520−01010, 09520−24010 (09520−32040)
NOTICE:
SBe careful not to damage the oil seal, boot and dust
cover.
SBe careful not to drop the drive shaft assy.
Page 4733 of 5135
C83155
F40218
SST
C91598
C86265
30−6
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
AVENSIS Supplement (RM1045E)
11. REMOVE FRONT DRIVE SHAFT ASSY RH (RH DRIVE
SHAFT)
(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:
SBe careful not to damage the oil seal, boot and dust
cover.
SBe careful not to drop the drive shaft assy.
12. FIX FRONT AXLE HUB LH BEARING
NOTICE:
The hub bearing may become damaged if subjected to the
vehicle weight. For example, 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)
13. INSPECT FRONT DRIVE SHAFT ASSY LH
(a) Check that there is no excessive 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 excessive 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.
14. 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 ifollwng the
same procedure as for the inboard joint boot LH No.2
clamp.
15. REMOVE FR AXLE INBOARD JOINT BOOT
(a) Remove the inboard joint boot from the inboard joint assy LH.
Page 4734 of 5135
C67413F45461
Matchmarks
G24058
C91601
Matchmarks
F44759
C81167
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
30−7
AVENSIS Supplement (RM1045E)
16. 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 use a punch for 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.
17. REMOVE FRONT DRIVE SHAFT DAMPER LH
(a) Using pliers, remove the damper clamp as shown in the
illustration.
(b) Remove the drive shaft damper.
18. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Using pliers, remove the outboard joint boot LH No.2
clamp as shown in the illustration.
(b) Remove the outboard joint boot LH clamp following the
same procedure as for the outboard joint boot LH No.2
clamp.
Page 4735 of 5135
C57543
F40647
SST
C67101
C68337
30−8
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
AVENSIS Supplement (RM1045E)
19. REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard joint shaft assy LH.
(b) Remove the old grease from the outboard joint.
20. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING
(a) Using a screwdriver, remove the hole snap ring.
21. REMOVE FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, remove the front drive shaft dust
cover LH.
SST 09950−00020
NOTICE:
Be careful not to drop the inboard joint assy.
22. REMOVE FRONT DRIVE SHAFT DUST COVER RH (RH
DRIVE SHAFT)
(a) Using a press, remove the drive shaft dust cover RH.
23. REMOVE CASE SUB ASSY, DRIVE SHAFT BEARING
SNAP RING (RH DRIVE SHAFT)
(a) Using a screwdriver, remove the bearing case snap ring.
Page 4736 of 5135
C68338
C68342F40208SST
C88701F45151
C68339F40210SST
C68340F40211
SST
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
30−9
AVENSIS Supplement (RM1045E)
24. REMOVE DRIVE SHAFT BEARING CASE SUB ASSY
(RH DRIVE SHAFT)
(a) Using a press, remove the drive shaft bearing case.
NOTICE:
Be careful not to drop the inboard joint assy.
25. REMOVE FRONT DRIVE SHAFT DUST COVER (RH
DRIVE SHAFT)
(a) Using SST and a press, remove the drive shaft dust cover.
SST 09950−00020
NOTICE:
Be careful not to drop the inboard joint assy.
26. REMOVE FRONT DRIVE SHAFT BEARING (RH DRIVE
SHAFT)
(a) Using a snap ring expander, remove the drive shaft hole
snap ring.
(b) Using SST and a press, remove the drive shaft bearing.
SST 09527−10011
(c) Remove the snap ring.
27. INSTALL FRONT DRIVE SHAFT BEARING (RH DRIVE
SHAFT)
(a) Using SST and a press, install a new drive shaft bearing.
SST 09950−60020 (09951−00710), 09950−70010
(09951−07100)