2005 TOYOTA AVENSIS Boot lock

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:

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.

F45439
Front Disc Brake Cylinder MountingBush Dust Boot
Lithium soap base glycol grease
F45701
Cylinder Slide Pin
Lithium soap base glycol grease
G23181
Union bolt
±
BRAKE REAR BRAKE
32±51
AVENSIS REPAIR MANUAL (RM1018E)
25.INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a)Apply lithium soap base glycol grease to the sealing sur-
face of 2 new bush dust boots.
(b)Install the 2 bush dust boots to the rear disc brake cylinder mounting LH.
26.INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN KIT
(a)Apply lithium soap base glycol grease to sealing surface of a new cylinder slide bush.
(b)Install the rear disc brake cylinder slide bush to the bottom side of the rear disc brake cylinder slide pin (No.2).
(c)Apply lithium soap base glycol grease to the sliding part and the sealing surface of the 2 rear disc brake cylinder
slide pins.
(d)Install the rear disc brake cylinder slide pin (No.1) and rear
disc brake cylinder slide pin (No.2) to the rear disc brake
cylinder mounting LH.
27.INSTALL REAR DISC BRAKE PAD KIT
(a)Install the 2 rear disc brake pad support plates No.1 and 2 rear disc brake pad\
support plate No.2 to the rear disc brake cylinder mounting LH.
(b)Install the disc brake pad kit rear to the disc brake cylinder mounting \
LH.
28.INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a)Install the disc brake cylinder assy rear LH with the 2 bolts.Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(b)Install a new gasket and flexible hose with the union bolt. Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
HINT:
Install the flexible hose lock securely in to the lock hole in the
disc brake cylinder assy rear LH.
29.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
30.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
31.BLEED BRAKE LINE (See page 32±4)
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)

D30594
F40050
Matchmarks
ZK8184
F40083
51±40
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
23. REMOVE RACK & PINION POWER STEERING GEAR
ASSY
(a) Remove the 4 bolts, the nuts and the power steering gear
assy from the crossmember sub±assy.
NOTICE:
Because the nut has its own stopper, do not turn the nut
and torque the bolt with the nut fixed.
24. REMOVE TIE ROD END SUB±ASSY LH
(a) Place matchmarks on the tie rod end sub±assy and the
rack end.
(b) Loosen the lock nut, and remove the tie rod end sub±assy
and the lock nut.
25. REMOVE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
26. INSPECT TIE ROD END SUB±ASSY LH
(a) Secure the tie rod end sub±assy in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torx wrench, turn the nut continuously at a rate of
2 to 4 seconds per turn and take the torque reading on the
5th turn.
Turning torque:
0.49 to 3.43 N
m (5.0 to 35 kgf
cm, 4.34 to 30.38 in. lbf)
27. INSPECT TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
28. REMOVE STEERING RACK BOOT NO.2 CLAMP
(a) Using a screwdriver, remove the rack boot No.2 clamp.
NOTICE:
Be careful not to damage the boot.

D30602
Tie Rod End Sub±assy RH
Lock NutSteering Rack Boot Clip
Steering Rack Boot No.1
Steering Rack Boot
No.1 Clamp

Lock Nut
Steering Rack
Boot No.2 Clamp

Steering Rack Boot
No.2
Steering Rack Boot Clip
Tie Rod End Sub±assy LH

Non±reusable part
Silicon greaseN
m (kgf
cm, ft
lbf) : Specified torque
74 (750, 54)
74 (750, 54)
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51±35
AVENSIS REPAIR MANUAL (RM1018E)

D30584
SST(s)
F40050
Matchmarks
C80324
F40259
Matchmarks
51±32
±
POWER STEERING STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL STEERING RACK BOOT CLIP
(a) Using a pliers, install the 2 rack boot clips to each rack boots.
(b) Using SST(s), check that the rack boot No.2 is strechy. SST 09616±00011
40. INSTALL TIE ROD END SUB±ASSY LH
(a) Screw the lock nut and the tie rod end sub±assy to the rack end sub±assy until the matchmarks are aligned.
Torque: 74 N
m (750 kgf
cm, 54 ft
lbf)
HINT:
After adjusting toe±in, torque the lock nut
(See page 26±6).
41. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side. 42. INSTALL STEERING GEAR ASSY
(a) Install the steering gear assy onto the crossmember sub±assy with the 4 bolts and the nuts.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
NOTICE:
Because the nut has its own stopper, do not turn the nut
and torque the bolt with the nut fixed.
43. INSTALL STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the steering intermediate shaft and the steering pinion shaft.
(b) Install the bolt. Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
44. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
45.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 51±36)

510DI±02
D30014
Stopper
Front
133 (1,356, 98)
89 (908, 66)
Front Stabilizer
Link Assy RH
74 (755, 55)
133 (1,356, 98)
80 (816, 59)
Stopper Rear
80 (816, 59)
52 (530, 38)
45 (459, 33)Center Member
52 (530, 38)
133 (1,356, 98)
Stopper Front
89 (908, 66)
80 (816, 59)
133 (1,356, 98)
80 (816, 59)
Stopper Rear
Crossmember
Bracket LH
74 (755, 55)
Front Stabilizer Link Assy LH
Front Suspension
Crossmember Sub±assy
Clip
Steering Intermediate Shaft
Assy No.2
35 (360, 26)
Steering Intermediate Shaft
Steering Column Hole
Cover Sub±assy No.1
Tie Rod End
Sub±assy RH
49 (500, 36)
74 (750, 54)
Lock Nut
Steering Rack
Boot Clip
Steering Rack
Boot No.1
49 (500, 36)
Steering Rack Boot
No.1 Clamp

Steering Rack
End Sub±assy
Lock Nut
Steering Rack Boot
No.2 Clamp

Steering Rack
Boot No.2
Steering Rack
Boot Clip
Tie Rod End
Sub±assy LH
49 (500, 36)

Cotter Pin
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part
Slicon grease
Engine Under Cover LH
Column Hole Cover
Silencer Sheet
Molybdenum disulfide lithium base grease
49 (500, 36)
49 (500, 36)
* For use with SST(s)
83.5 (851, 62)
*60 (616, 45)
74 (750, 54)
± POWER STEERINGSTEERING GEAR ASSY
51±27
AVENSIS REPAIR MANUAL (RM1018E)
STEERING GEAR ASSY
COMPONENTS

410DI±01



D30695
Select Spring Seat No.2


Apply MP greaseSelect Spring No.2 Seat E Ring
Shift Lever Inner No.1
Shift Inner Lever Slotted Spring Pin Select Return Compression Spring No.2
Shift Lever Inner No.2
Shift Inter Lock Plate
Select Inner Lever
Select Return Compression Spring No.1
Select Inner Lever Slotted Spring Pin
Select Spring Seat No.1
Select Spring No.1 Seat Shaft Snap Ring
Shift & Select Lever Shaft
Control Shift Lever Retainer Gasket
Control Shaft Cover
Control Shaft Cover Oil SealShift & Select Lever Shaft Dust Boot
41±58
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
SHIFT & SELECT LEVER SHAFT ASSY (C250)
COMPONENTS