Toyota Corolla (2004+). Manual

26-12

FRONT SUSPENSION

- FRONT SHOCK ABSORBER WITH COIL SPRING

2607W-01

DISPOSAL

DISPOSE SHOCK ABSORBER ASSY FRONT LH

(a) Fully extend the shock absorber piston rod.

(b) Using a drill, make a hole in the cylinder as shown in the

illustration to discharge the gas inside.

CAUTION:

When drilling, chips may fly out, work carefully.

The gas is colorless, odorless and non-poisonous.

F13693

26-8

FRONT SUSPENSION

- FRONT SHOCK ABSORBER WITH COIL SPRING

FRONT SHOCK ABSORBER WITH COIL SPRING

2607V-01

OVERHAUL

HINT:

COMPONENTS: See page 26-3

REMOVE FRONT WHEEL

DISCONNECT FRONT STABILIZER LINK ASSY LH

(a) Remove the nut and disconnect the front stabilizer link

assy LH from the shock absorber assy front LH.

HINT:

If the ball joint turns together with the nut, use a hexagon (6 mm)

wrench to hold the stud.

F13686

DISCONNECT FRONT FLEXIBLE HOSE

(a) w/ ABS:

Remove the bolt, disconnect the front flexible hose No. 1

and speed sensor front LH.

(b) w/o ABS:

Remove the bolt, disconnect the front flexible hose.

C80880

REMOVE FRONT SHOCK ABSORBER WITH COIL

SPRING

(a) Remove the 2 bolts and nuts on the lower side of the

shock absorber assy front LH.

NOTICE:

When removing the bolt, stop the bolt from rotating and

loosen the nut.

F13687

(b) Remove the 3 nuts on the upper side of the shock absorb-

er assy front LH.

(c)

Remove the front shock absorber with the coil spring.

C95202

26-9

FRONT SUSPENSION

- FRONT SHOCK ABSORBER WITH COIL SPRING

FIX FRONT SHOCK ABSORBER WITH COIL SPRING

(a) Install 2 nuts and a bolt to the bracket at the lower side of

the shock absorber assy front LH and secure it in a vise.

28 mm

(1.1 in.)

F13688

REMOVE SHOCK ABSORBER ASSY FRONT LH

(a) Remove the front suspension support dust cover LH from

the front suspension support sub-assy LH.

(b) Using SST, compress the front coil spring LH.

SST

09727-30021

NOTICE:

Do not use an impact wrench. It will damage the SST.

F13689

(c)

Using SST to hold the front coil spring seat upper LH, re-

move the nut.

SST

09729-22031

(d) Remove the front suspension support sub-assy LH, front

suspension support LH dust seal, front coil spring seat

upper LH, front coil spring insulator upper LH, front coil

SST

spring LH, front spring bumper LH and front coil spring in-

sulator lower LH.

F13690

INSPECT SHOCK ABSORBER ASSY FRONT LH

(a) 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

F13691

page 26-12.

INSTALL SHOCK ABSORBER ASSY FRONT LH

(a) Install the front coil spring insulator lower LH onto the

shock absorber assy front LH.

(b) Install the front spring bumper LH to the shock absorber

piston rod.

26-10

FRONT SUSPENSION

- FRONT SHOCK ABSORBER WITH COIL SPRING

(c)

Using SST, compress the front coil spring LH.

SST

09727-30021

SST

NOTICE:

Do not use an impact wrench. It will damage the SST.

(d) Install the front coil spring LH to the shock absorber assy

front LH.

HINT:

Fit the lower end of the front coil spring LH into the gap of the

F40271

spring lower seat.

(e) Install the front coil spring insulator upper LH as shown in

the illustration.

Outside

F13692

(f)

Install the front coil spring seat upper LH to the shock ab-

Outside

sorber assy front LH with the mark facing the outside of

the vehicle.

(g) Install the front suspension support LH dust seal and front

suspension support sub-assy LH.

F40272

(h) Using SST to hold the front coil spring seat upper LH,

install a new nut.

SST

09729-22031

Torque: 47 N m (479 kgf cm, 35 ft lbf)

(i)

Remove the SST.

(j)

Install the front suspension support dust cover LH.

SST

F13690

(k)

Apply MP grease No.2 into the suspension support sub-

MP Grease No.2

assy LH.

CAUTION:

Do not touch grease on rubber surface of upper support.

F40273

26-11

FRONT SUSPENSION

- FRONT SHOCK ABSORBER WITH COIL SPRING

INSTALL FRONT SHOCK ABSORBER WITH COIL

SPRING

(a) Install the shock absorber with the 2 bolts.

(b) Install the 3 nuts to the upper side of front shock absorber

with coil spring.

Torque: 39 N m (398 kgf cm, 29 ft lbf)

C95202

(c)

Install the 2 bolts and nuts to the lower side of front shock

absorber with coil spring.

Torque: 153 N m (1,560 kgf cm, 113 ft lbf)

NOTICE:

When installing bolt, stop the bolt from rotating and torque

the nut.

F13687

10. INSTALL FRONT FLEXIBLE HOSE

(a) w/ ABS:

Install the front flexible hose and speed sensor front LH

with the bolt.

Torque: 29 N m (296 kgf cm, 21 ft lbf)

(b) w/o ABS:

Install the front flexible hose with the bolt.

Torque: 29 N m (296 kgf cm, 21 ft lbf)

C80880

11. INSTALL FRONT STABILIZER LINK ASSY LH

(a) Install the front stabilizer link assy LH 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

wrench (6 mm) to hold the stud.

F13686

12. INSTALL FRONT WHEEL

Torque: 103 N m (1,050 kgf cm, 76 ft lbf)

13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26-5)

26-19

FRONT SUSPENSION

- STABILIZER BAR FRONT

STABILIZER BAR FRONT

2607Z-01

REPLACEMENT

HINT:

COMPONENTS: See page 26-3

REMOVE FRONT WHEEL

REMOVE FRONT STABILIZER LINK ASSY LH

(a) Remove the 2 nuts and stabilizer bar link.

HINT:

If the ball joint turns together with the nut, use a hexagon

wrench (6 mm) to hold the stud.

C80890

REMOVE FRONT STABILIZER LINK ASSY RH

HINT:

Remove the RH side by the same procedure as the LH side.

INSPECT FRONT STABILIZER LINK ASSY

(a) As shown in the illustration, flip the ball joint stud back and

forth 5 times, before installing the nut.

(b) Using a torque wrench, turn the nut continuously at a rate

of 2 - 4 seconds per 1 turn and take the torque reading

on the 5th turn.

Turning torque:

0.05 - 1.96 Nm (0.5 - 20 kgf cm, 0.4 - 17 in. lbf)

C66721

SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH(See page 26-13)

SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH

HINT:

Remove the RH side by the same procedure as the LH side.

SEPARATE RACK & PINION POWER STEERING GEAR ASSY(See page 26-13)

SUSPEND ENGINE ASSY

AT: (See page 40-9)

MT: (See page 41-17)

SEPARATE FRONT SUSPENSION CROSSMEMBER SUB-ASSY(See page 26-13)

10. REMOVE STABILIZER BAR FRONT

(a) Remove the 4 bolts,front stabilizer bracket No.1 LH, front stabilizer bracket No.1 RH, 2 front stabilizer

bar bushes No.1 and stabilizer bar front from the front suspension crossmember sub-assy.

(b) Remove the 2 front stabilizer bar bushes No.1 from the stabilizer bar front.

26-20

FRONT SUSPENSION

- STABILIZER BAR FRONT

11. INSTALL STABILIZER BAR FRONT

Inner side

(a) Install 2 front stabilizer bar bushes No.1, front stabilizer

bracket No.1 LH and front stabilizer bracket No.1 RH to

the stabilizer bar front.

HINT:

Install the bushing to the inner side of the bushing stopper on

Rear

side

the stabilizer bar.

C81547

F40197

(b) Install the stabilizer bar front and 4 bolts to the front sus-

pension crossmember sub-assy.

Torque: 19 N m (194 kgf cm, 14 ft lbf)

C91627

12. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY(See page 26-13)

SST

09670-00010

13. INSTALL RACK & PINION POWER STEERING GEAR ASSY(See page

26-13)

14. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH(See page

26-13)

15. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH

HINT:

Install the RH side by the same procedures as the LH side.

16. INSTALL FRONT STABILIZER LINK ASSY LH

(a) Install the stabilizer bar link with the 2 nuts.

Torque: 74 N m (755 kgf cm, 55 ft lbf)

HINT:

If the ball joint turns together with the nut, use a hexagon

wrench (6 mm) to hold the stud.

C80890

17. INSTALL FRONT STABILIZER LINK ASSY LH

HINT:

Install the RH side by the same procedure as the LH side.

18. INSTALL FRONT WHEEL

Torque: 103 N m (1,050 kgf cm, 76 ft lbf)

19. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26-5)

FRONT SUSPENSION

- FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1

26-13

FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH

2607X-01

REPLACEMENT

HINT:

COMPONENTS: See page 26-3

REMOVE FRONT WHEEL

DISCONNECT FRONT STABILIZER LINK ASSY LH (LH (A/T) POSITION)(See page

26-8)

DISCONNECT FRONT STABILIZER LINK ASSY RH (LH (A/T) POSITION)

HINT:

Remove the RH side by the same procedures as the LH side.

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 assy front LH.

C80293

SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH (LH (A/T) POSITION)

HINT:

Remove the RH side by the same procedures as the LH side.

SEPARATE RACK & PINION POWER STEERING GEAR ASSY (LH (A/T) POSITION)

(a) Remove the 4 bolts, separate the rack & pinion power steering gear assy.

NOTICE:

Loosen the bolt since the nut cannot be rotated.

(b) Suspend the rack & pinion power steering gear assy.

SUSPEND ENGINE ASSY (LH (A/T) POSITION)(See page 40-9)

SEPARATE FRONT SUSPENSION CROSSMEMBER

SUB-ASSY (LH (A/T) POSITION)

(a) Remove the 3 bolts and 3 nuts, disconnect the transverse

engine engine mounting insulator and engine mounting

member sub-assy center from the front suspension

crossmember sub-assy.

C86742

26-14

FRONT SUSPENSION

- FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1

(b) Remove the 4 bolts.

(c)

Lower the transmission jack, remove the front suspension

crossmember sub-assy.

C87404

REMOVE FRONT SUSPENSION ARM SUB-ASSY

LOWER NO.1 LH

(a) Remove the 2 bolts, nut and front suspension arm sub-

assy lower No.1 LH from the front suspension crossmem-

ber sub-assy.

C87403

10.

TEMPORARY TIGHTEN FRONT SUSPENSION ARM

SUB-ASSY LOWER NO.1 LH

(a)

Install the front suspension arm sub-assy lower No. 1 LH,

temporarily tighten the 2 bolts and nut.

11.

INSTALL FRONT SUSPENSION CROSSMEMBER

SUB-ASSY (LH (A/T) POSITION)

(a)

Lift the front suspension crossmember sub-assy up with

a transmission jack.

C87403

(b)

Insert SST to the base hole of the RH side crossmember

and RH side of the vehicle.

SST

09670-00010

(c)

Tighten the bolt temporarily in the order A and B.

SST

C64941

C65019

(d)

Insert SST to the base hole of the LH side of crossmem-

ber and LH side of the vehicle.

SST

09670-00010

(e)

Tighten the bolt temporarily in the order A and B.

(f)

Insert SST to the base hole of the RH side of crossmem-

ber and RH side of the vehicle.

SST

09670-00010

C64940

C65020

FRONT SUSPENSION

- FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1

26-15

(g) Then tighten the bolt A and B by the specified torque.

Torque:

Bolt A: 157 N m (1,601 kgf cm, 116 ft lbf)

Bolt B: 113 N m (1,152 kgf cm, 83 ft lbf)

(h) Insert SST to the base hole of the LH side of crossmem-

ber and LH side of the vehicle.

SST

09670-00010

(i)

Tighten the bolt A and B by the specified torque.

Torque:

Bolt A: 157 N m (1,601 kgf cm, 116 ft lbf)

Bolt B: 113 N m (1,152 kgf cm, 83 ft lbf)

(j)

Connect the transverse engine engine mounting insula-

tor and engine mounting member sub-assy center to the

front suspension crossmember sub-assy.

(k)

Install the 3 bolts and 3 nuts.

Torque: 52 N m (530 kgf cm, 38 ft lbf)

C86742

12. INSTALL RACK & PINION POWER STEERING GEAR ASSY (LH (A/T) POSITION)

(a) Install the rack & pinion power steering gear assy with the 4 bolts.

Torque: 58 N m (591 kgf cm, 43 ft lbf)

13. INSTALL FRONT SUSPENSION ARM SUB-ASSY

LOWER NO.1 LH

(a) Install the front suspension arm sub-assy lower No.1 LH

with the 2 nuts and bolt to the lower ball joint assy front LH.

Torque: 89 N m (908 kgf cm, 66 ft lbf)

C80293

14. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH (LH (A/T) POSITION)

HINT:

Install the RH side by the same procedures as the LH side.

15. INSTALL FRONT STABILIZER LINK ASSY LH (LH (A/T) POSITION)(See page

26-8)

16. INSTALL FRONT STABILIZER LINK ASSY RH (LH (A/T) POSITION)

HINT:

Install the RH side by the same procedure as the LH side.

26-16

FRONT SUSPENSION

- FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1

17. STABILIZE SUSPENSION

(a) Install the front wheel and jack down the vehicle.

Torque: 103 N m (1,050 kgf cm, 76 ft lbf)

(b) Bounce the vehicle up and down several times to stabilize the suspension.

18. FULLY TIGHTEN FRONT SUSPENSION ARM

SUB-ASSY LOWER NO.1 LH

(a) Fully tighten the 2 bolts and nut.

Torque: 137 N m (1,397 kgf cm, 101 ft lbf)

NOTICE:

Tighten the bolt since the nut cannot be rotated.

C87403

19. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26-5)

26-1

FRONT SUSPENSION

- FRONT SUSPENSION SYSTEM

FRONT SUSPENSION SYSTEM

2607R-01

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

Suspect Area

See page

1. Vehicle (Overloaded)

Bottoming

2. Spring (Weak)

26-8

3. Shock absorber (Worn)

26-8

1. Tire (Worn or improperly inflated)

28-1

Sways/pitches

2. Stabilizer bar (Bent or broken)

26-19

3. Shock absorber (Worn)

26-8

1. Tire (Worn or improperly inflated)

28-1

2. Wheel (Out of balance)

28-1

3. Shock absorber (Worn)

26-8

4. Wheel alignment (Incorrect)

26-5

Front wheel shimmy

27-3

5. Ball joint (Worn)

26-17

30-17

6. Hub bearing (Worn)

7. Steering linkage (Loose or worn)

1. Tire (Worn or improperly inflated)

28-1

2. Wheel alignment (Incorrect)

26-5

Abnormal tire wear

27-3

3. Shock absorber (Worn)

26-8

4. Suspension parts (Worn)

27-2

REAR SUSPENSION

- REAR SUSPENSION

REAR SUSPENSION

2707O-01

COMPONENTS

56 (571, 41)

Suspension Plate

Cushion

Spring Bracket

80 (816, 59)

Suspension Support

Upper Insulator

80 (816, 59)

Spring Bumper

5.0 (51, 44 in. lbf)

Coil Spring

Rear Shock Absober

Rear Shock Absorber

w/Coil Spring

Assy Rear LH

80 (816, 59)

Speed Sensor Wire

5.4 (55, 48 in. lbf)

Rear Brake

Drum Sub-Assy

195 (1,990, 144)

Stabilize Bar Rear

61 (622, 45)

Rear Axle Carrier

Bush LH

195 (1,990, 144)

85 (867, 62)

Rear Axle Carrier

Bush LH

Nm (kgfcm, ftlbf)

: Specified torque

Rear Axle Beam Assy

F Non-reusable part

C95124

27-3

REAR SUSPENSION

- REAR WHEEL ALIGNMENT

REAR WHEEL ALIGNMENT

2707P-01

INSPECTION

INSPECT TIRE(See page 28-1)

MEASURE VEHICLE HEIGHT(See page 26-5)

NOTICE:

Before inspecting the wheel alignment, adjust the vehicle height to the specified value.

INSPECT TOE-IN

Toe-in:

Front

USA, Canada:

P195/65R15 89S

P185/65R15 86S

0°16’ ± 16’

A + B

(0.26° ± 0.26°)

2.6 ± 2.5 mm

2.5 ± 2.5 mm

C - D

(0.10 ± 0.10 in.)

Mexico:

SA3213

P195/65R15 89H

A + B

0°01’ ± 16’ (0.16° ± 0.26°)

C - D

1.6 ± 2.5 mm (0.06 ± 0.10 in.)

If the toe-in is not within the specified value, inspect and re-

place the suspension parts as necessary.

INSPECT CAMBER

(a) Install the camber-caster-kingpin gauge or position vehicle on wheel alignment tester.

(b) Inspect the camber.

Camber:

USA, Canada

Mexico

Camber

-1°27’ ± 30’ (-1.45° ± 0.5°)

-1°26’ ± 30’ (-1.43° ± 0.5°)

Right-left error

30’ (0.5°) or less

If the measured value is not within the specified value, inspect the suspension parts for damage and/or wear

and replace them if necessary become camber is not adjustable.

27-8

REAR SUSPENSION

- REAR AXLE BEAM ASSY

REAR AXLE BEAM ASSY

2707S-02

REPLACEMENT

HINT:

COMPONENTS: See page 27-2

REMOVE REAR WHEEL

(a) Remove the RH and LH rear wheels.

REMOVE REAR BRAKE DRUM SUB-ASSY(See page 32-31)

SEPARATE SKID CONTROL SENSOR WIRE

(a) Disconnect the skid control sensor connector.

(b) Remove the 2 bolts and separate the wire harness

clamps.

(c)

Remove the bolt and separate parking brake cable

clamp.

(d) Using the same manner desoribed above to the other

side.

C68929

REMOVE STABILIZER BAR REAR(See page 27-13)

REMOVE REAR AXLE HUB & BEARING ASSY LH

(a) Remove the 4 bolts and rear axle hub from the axle beam.

C66800

REMOVE REAR AXLE HUB & BEARING ASSY RH

HINT:

Remove the RH side by the same procedures with the LH side.

SEPARATE REAR SHOCK ABSORBER WITH COIL

SPRING

(a) Remove the nut, washer and separate the rear shock ab-

sorber w/coil spring (lower side) from the rear axle beam.

(b) Using the same manner desoribed above to the other

side.

C67565

Toyota Corolla (2004+). Manual - part 15