2005 TOYOTA AVENSIS height

D25320
No.2 Engine Hanger
No.1 Engine Hanger
Front: Rear:
D30483
D30484
C70065
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±17
AVENSIS REPAIR MANUAL (RM1018E)
27. SUSPEND ENGINE ASSY
(a) Remove the 2 PCV hoses.
(b) Install the 2 hangers in the correct direction.
No.1 engine hanger: 12281±22021
No.2 engine hanger: 12281±15040
Bolt: 91512±B1016
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(c) Attach the engine chain hoist to the hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
28. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
29.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY(See page 26±26)
30. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the transaxle with a transmission jack.
31. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator LH from the body.
32. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from the transaxle.
33. REMOVE MANUAL TRANSAXLE ASSY
(a) Remove the 6 bolts and transaxle from the engine.

D30484
D30483
A
A
A
A
B
D11561
(a)
(c)
(b)(a)
G24210
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±19
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket LH to the transaxle
with the 3 bolts.
Torque: 64 N
m (653 kgf
cm, 47 ft
lbf)
40. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Install the engine mounting insulator LH with the 5 bolts and nut.
Torque:
Bolt A: 52 N
m (530 kgf
cm, 38 ft
lbf)
Bolt B: 80 N
m (816 kgf
cm, 59 ft
lbf)
41.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26) SST 09670±00010
42. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP) (See page 65±28)
43.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
44.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
45. INSTALL STARTER ASSY
(a) Install the starter assy and 2 bolts to the transaxle.Torque: 37 N
m (380 kgf
cm, 27 ft
lbf)
(b) Connect the starter connector.
(c) Install the wire and nut to the starter assy.
Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
46. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Connect the 2 cable ends, install the 2 clips.
(b) Install the 2 clips to the control cable bracket.

D29965
RHD:
LHD:
SST(s)
SST(s)
D29966
RHD:
LHD:
SST(s)
SST(s)
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±37
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
11. DISCONNECT STEERING GEAR OUTLET RETURNTUBE
(a) Using SST(s), disconnect the outlet return tube. SST 09023±12700
(b) LHD: Remove the bolt and separate the tube clamp from the
power steering gear assy.
12. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Using SST(s), disconnect the pressure feed tube assy. SST 09023±12700
13.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
14. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.



D30705
LHD:
A
B
RHD:
Matchmarks
Matchmarks
A
B
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±45
AVENSIS REPAIR MANUAL (RM1018E)
50. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
51.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
52. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
53. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
54. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
55. INSTALL STEERING INTERMEDIATE SHAFT ASSYNO.2
(a) Align the matchmarks on the intermediate shaft assy No.2 and the intermediate shaft.
(b) Install the bolt B and tighten the bolt A. Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
56.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
57. INSTALL CYLINDER HEAD COVER SUB±ASSY
58.ADD POWER STEERING FLUID (See page 51±4)
59.BLEED POWER STEERING FLUID (See page 51±4)
60.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
61. INSPECT FLUID LEAK
62.INSPECT HOOD SUB±ASSY (See page 75±2)
63.ADJUST HOOD SUB±ASSY (See page 75±2)
64.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
65. INSTALL ENGINE UNDER COVER LH
66. INSTALL ENGINE UNDER COVER RH
67.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)

510DJ±02
D25320
No.1 Engine HangerNo.2 Engine Hanger
Front:Rear:
51±28
±
POWER STEERING STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
NOTICE:
When installing, coat the parts indicated by the arrows with power steering fluid or molybdenum dis-
ulfide lithium base grease (See page 51±27).
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
4. SEPARATE STEERING COLUMN HOLE COVER SUB±ASSY NO.1
5. REMOVE FRONT WHEELS
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE ENGINE UNDER COVER RH
8.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
9. SEPARATE TIE ROD END SUB±ASSY RH SST 09628±62011
HINT:
Perform the same procedure on the other side.
10. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
11.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
12. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.
13.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
14. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
15. REMOVE HOOD SUB±ASSY
16. REMOVE CYLINDER HEAD COVER SUB±ASSY
17. SUSPEND ENGINE ASSEMBLY
(a) Remove the 2 PCV hoses.
(b) Install the 2 engine hangers in the correct direction.No.1 engine hanger: 12281±22021
No.2 engine hanger: 12281±15040
Bolt: 90512±B1016
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(c) Attach the engine chain hoist to the hangers.
CAUTION:
Do not attempt t hang the ingine by hooking the chain to
any other part.
18.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 51±36)
19. REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1

±
POWER STEERING STEERING GEAR ASSY
51±33
AVENSIS REPAIR MANUAL (RM1018E)
46.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
47. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
48.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
49. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.
50. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
51.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
52. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
53. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
54. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
55.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
56.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
57. INSTALL CYLINDER HEAD COVER SUB±ASSY
58.INSPECT HOOD SUB±ASSY (See page 75±2)
59.ADJUST HOOD SUB±ASSY (See page 75±2)
60.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
61. INSTALL ENGINE UNDER COVER LH
62. INSTALL ENGINE UNDER COVER RH
63.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)

± LIGHTINGLIGHTING SYSTEM
65±7
AVENSIS REPAIR MANUAL (RM1018E)
(b) Connect the connector to the headlamp leveling ECU
assy, then turn the ignition switch ON and light control
switch into HEAD position. Inspect the wire harness side
connector from the back side as shown in the chart.
Standard:
Tester connectionConditionSpecified condition
2 ± body groundAlways5 V
3 ± body ground3 secs. after vehicle height change for 10 secs.1.0 to 13 V
4 ± body ground3 secs. after vehicle height change for 10 secs.1.0 to 13 V
5 ± body groundAlways0 to 5 V
6 ± body groundAlways0 to 5 V
10 ± body groundHeadlamp Switch is OFF
ON10 to 14 V
Below 1 V
11 ± body groundBeam level warning light OFF
ON10 to 14 V
Below 1 V
12 ± body groundTurn the vehicle wheelPuls generation
13 ± body groundAlways10 to 14 V
14 ± body groundAlways10 to 14 V
15 ± body groundAlways5 V
20 ± body groundAlwaysBelow 1 V
21 ± body groundAlwaysBelow 1 V
22 ± body groundAlwaysBelow 1 V
23 ± body groundAlwaysBelow 1 V
4. HEADLAMP AUTO LEVERING OPERATION CHECK
(a) Check that the initialization (determination of the initial position) for the leveling motor is performed at
the engine±start.
(b) Check that the warning indicator in the combination meter assy illuminates for approximately 3 se-
conds at the engine±start and then goes off.
(c) Check that the reflector works when:
Keeping the rear of the vehicle up or down while the engine is running with the vehicle stopped and
the headlamp dimmer switch in the HEAD position.
NOTICE:
Make sure to change the vehicle's height slowly.
5. FAIL±SAFE FUNCTION
(a) Headlamp Leveling Control ECU
HINT:
The Headlamp Leveling Control ECU performs the fail±safe when detecting following troubles. At this the
warning indicator light on the combination meter lights up.
Trouble AreaConditionHeadlight levering motor
1. Height control sensor
Signal level error

Out of voltageStop leveling operation
2. Headlamp leveling control ECU
Watchdock detection

High voltageStop leveling operation

±
LIGHTING LIGHTING SYSTEM
65±3
AVENSIS REPAIR MANUAL (RM1018E)
3. TURN SIGNAL AND HAZARD WARNING SYSTEM
SymptomSuspect AreaSee page
ºHazardº and ºTurnº do not come on.
1. HAZARD fuse
2. GAUGE2 fuse
3. IG1 relay
4. Ignition switch
5. Turn signal flasher relay
6. Harness or connector±
±
±
±
65±5
±
Hazard warning light does not come on.
(Turn is normal)1. Hazard warning switch
2. Harness or connector65±9±
Turn signal does not come on.
(Hazard is normal)1. Headlamp dimmer switch (turn signal switch)
2. Harness or connector65±9±
Turn signal does not come on in one direction.1. Headlamp dimmer switch (turn signal switch)
2. Harness or connector65±9±
Only one bulb does not come on.1. Bulb
2. Harness or connector±
±
4. ILLUMINATED ENTRY SYSTEM
SymptomSuspect AreaSee page
Illumination lamp of Multiplex body ECU control does not come
on.
1. Ignition switch
2. Door courtesy switch
3. Door lock position switch
4. Harness or connector
5. Integration relay±
65±9
05±1534 ±
±
Illumination lamp of Multiplex body ECU control does not go off.
1. Ignition switch
2. Door courtesy switch
3. Door lock position switch
4. Harness or connector
5. Integration relay±
65±9
05±1534 ±
±
5. HEADLIGHT BEAM LEVEL CONTROL SYSTEM (W/O HID)
SymptomSuspect AreaSee page
Headlight beam level control system does not operate (All).
1. TAIL relay
2. Headlamp leveling switch
3. Harness or connector±
65±9 ±
Headlight beam level control system does not operate (One side).
1. Headlamp leveling switch
2. Headlight beam level control actuator
3. Harness or connector65±9
65±5±
6. HEADLIGHT BEAM LEVEL CONTROL SYSTEM (W/ HID)
SymptomSuspect AreaSee page
Headlight beam level control system does not operate (All).
1. GAUGE2 fuse
2. Ignition switch
3. Speed sensor signal circuit
4. Height control sensor sub±assy
5. Headlamp leveling ECU assy
6. Harness or connector±
±
±
65±9
65±5 ±
Headlight beam level control system does not operate (One side).
1. Headlamp leveling ECU assy
2. Headlight beam level control actuator
3. Harness or connector65±5
65±5±
Beam level warning light comes on.
1. Height control sensor sub±assy
2. Headlamp leveling ECU assy
3. Harness or connector65±9
65±5±