height TOYOTA AVENSIS 2005 Service User Guide

F45154
Rack & Pinion
Power Steering Gear Assy
Tie Rod End
Sub±assy LH
Front Stabilizer Link
Assy LH
Stabilizer Bar Front Front Stabilizer Link
Assy RH
Front Suspension Arm
Sub±assy Lower No.1 RH
Front Suspension
Member Brace
Rear RHFront Stabilizer
Bar Bush No.1
Front Suspension
Crossmember Sub±assy
Front Suspension
Arm Sub±assy
Lower No.1 LH
Body Mounting
Stopper Rear
Front Suspension
Member Body
Mounting Stopper FR
Front Suspension
Member Brace Rear LH
Cotter Pin

89 (908, 66)
133 (1,360, 98)
49 (500, 36)
74 (755, 55)
80 (816, 59)
133 (1,360, 98)
74 (755, 55)
49 (500, 36)
80 (816, 59)
19 (194, 14)
19 (194, 14)
133 (1,360, 98)
80 (816, 59)
133 (1,360, 98)
80 (816, 59)
19 (194, 14)
49 (500, 36)
74 (755, 55)
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

5.4 (55, 48 in.
lbf)w/ HID:
HID Height
Control Sensor
Front Stabilizer
Bracket No.1 RH
Front Stabilizer
Bracket No.1 LH
96 (979, 71)
80 (816, 59)
52 (530, 38)
± FRONT SUSPENSIONFRONT SUSPENSION
26±5
AVENSIS REPAIR MANUAL (RM1018E)

270E1±01
SA3213
AD B
Front
C
G23862
27±4
±
REAR SUSPENSION REAR WHEEL ALIGNMENT
AVENSIS REPAIR MANUAL (RM1018E)
REAR WHEEL ALIGNMENT
ADJUSTMENT
1.INSPECT TIRE (See page 28±1)
2.MEASURE VEHICLE HEIGHT (See page 26±6)
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle height to the \
specified value. 3. INSPECT TOE±IN
Toe±in:
(Normal package)
Toe±in(total)A + B: 0 18' \b 12' (0.3  \b 0.2 )
C ± D: 3.0 \b 2.0 mm (0.12 \b 0.08 in.)
(Rough road package)
Toe±in
(total)A + B: 0 ' \b 12' (0.3  \b 0.2 )
C ± D: 3.0 \b 2.0 mm (0.12 \b 0.08 in.)
If the toe±in is not within the specified value, inspect the sus-
pension parts and replace them if necessary.
4. INSPECT CAMBER
(a) Install the camber±caster±kingpin gauge or position the vehicle on\
the wheel alignment tester.
(b) Inspect the camber.
Camber:
(Normal package)
Camber
Right±left error±0 ' \b 30' (±0.9  \b 0.5 )
30' (0.5 ) or less
(Rough road package)
Camber
Right±left error±0
' \b 30' (±0.5  \b 0.5 )
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 because camber is not adjustable.
5. ADJUST CAMBER AND TOE±IN
(a) Measure the distance from the LH rear suspension armbracket assy set bolt to the RH rear axle carrier rear side
set bolt as shown in the illustration.
(b) Measure the distance from the RH rear suspension arm bracket assy set bolt to the LH rear axle carrier rear side
set bolt as shown in the illustration.
(c) Employ the same manner to the LH±RH.
Length difference: 6.0 mm (0.236 in.) or less
If the difference exceeds the specified value, adjust it by turning
the camber adjusting cam assy and tie rod adjusting tube.

270E0±01

G26285
w/ Height Control Sensor:
5.8 (59, 51 in.
lbf)
80 (816, 59)
Rear Suspension Member Sub±assy
Rear Shock Absorber
Cushion Washer No.1
Coil Rear Spring
Rear Coil Spring Insulator Upper LH
Rear Spring Bumper No.1 LH
Rear Suspension Support Assy LH
Rear Spring Front Bracket
Sub±assy LH
Rear Shock
Absorber Cushion No.1
Lower Control Arm Assy RH
Rear Shock Absorber
Assy LH
160 (1,632, 118)
110 (1,122, 81)
65 (663, 48)
Rear Suspension
Support Stopper
Rear Suspension Arm
Bracket Assy LH
Rear Suspension
Arm Bush No.1
Camber Adjust Cam Assy
Rear Suspension Arm Assy No.1 LH
74 (755, 55)
105 (1,071, 77)
44 (449, 32)
74 (755, 55)
74 (755, 55)
Parking Brake Cable Assy No.3
5.0 (51, 44 in.
lbf)Rear Axle Carrier Sub±assy LH
Skid Control Sensor Wire
74 (755, 55)
Upper Control Arm Assy
Camber Adjust Cam No.2
Lower Control Arm Assy LH
105 (1,071, 77)
5.0 (51, 44 in.
lbf)
60 (612, 44)
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

56 (571, 41)

56 (571, 41)
Clip
Clip 27±2
± REAR SUSPENSIONREAR SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION
COMPONENTS

F45155

F40197
Inner SideRear
Side
±
FRONT SUSPENSION STABILIZER BAR FRONT
26±27
AVENSIS REPAIR MANUAL (RM1018E)
10. SUSPEND ENGINE ASSY
(a)1ZZ, 3ZZ Engine: See page 41±15
(b)1AZ Engine: See page 41±24
(c)1CD Engine: See page 41±33
11.REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
12. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Remove the RH side by the same procedures as the LH side.
13.SEPARATE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
14. REMOVE FRONT STABILIZER BRACKET NO.1 LH
(a) Remove the 2 bolts and the front stabilizer bracket No.1 LH.
15. REMOVE FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID:Remove the 3 bolts, the front stabilizer bracket No.1 RH
and the height control sensor (Front).
(b) w/o HID:
Remove the 2 bolts and the front stabilizer bracket No.1
RH.
16. REMOVE FRONT STABILIZER BAR BUSH NO.1
(a) Remove the 2 bushings from the stabilizer bar.
17. REMOVE STABILIZER BAR FRONT
18. INSTALL STABILIZER BAR FRONT 19. INSTALL FRONT STABILIZER BAR BUSH NO.1
(a) Install the 2 front stabilizer bar bush No.1 to the stabilizerbar front as shown in the illustration.
HINT:
Install the bushing to the outer side of the bushing stopper on
the stabilizer bar.
20. INSTALL FRONT STABILIZER BRACKET NO.1 LH
(a) Install the front stabilizer bracket No.1 LH with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)

F45155
A
B
F44620
26±28
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
21. INSTALL FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID: Install the front stabilizer bracket No.1 RH and the height
control sensor (Front) with the 3 bolts.
Torque:
Bolt A: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
Bolt B: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b) w/o HID: Install the front stabilizer bracket No.1 RH with the 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
22.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
23.INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
24. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
25. INSTALL RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
26.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
27. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
28.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
29. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side.
30. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH 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.
31. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
32. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
33.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
34.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)

C95317
C86742
C87504
C95318
± FRONT SUSPENSIONFRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)26±17
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE FRONT SUSPENSION MEMBER BRACE
REAR LH
(a) Support the front suspension crossmember sub±assy
with a transmission jack.
(b) Remove the 4 bolts and front suspension member brace
rear LH.
(c) Remove the front suspension member body mounting
stopper rear from the front suspension member brace
rear LH.
11. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Remove the RH side by the same procedures as the LH side.
12. SEPARATE FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) w/ HID:
Disconnect the height control sensor (Front) connector.
(b) 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.
(c) Remove the 2 nuts and 2 front suspension member body
mounting stoppers front.
(d) Lower the transmission jack, remove the front suspension
crossmember sub±assy.
13. REMOVE FRONT SUSPENSION ARM SUB±ASSY
LOWER NO.1 LH
(a) Remove the 2 bolts, nut and lower suspension arm sub±
assy lower No.1 LH from the front suspension crossmem-
ber sub±assy.

C95318
C87504
C86742
AA
AAB
B
C95317
AA
A
B
26±18
±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH(ATM)
AVENSIS REPAIR MANUAL (RM1018E)
14.TEMPORARILY TIGHTEN FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a)Install the lower suspension arm sub±assy lower No.1
LH, and temporarily tighten the 2 bolts and nut.
15.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY
(a)Support the front suspension crossmember sub±assy with a transmission jack.
(b)Install the 2 front suspension member body mounting stoppers front and 2 nuts.
Torque: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
(c)Connect the transverse engine engine mounting insula- tor and engine mounting member sub±assy center to the
front suspension crossmember sub±assy.
(d)Install the 3 bolts and 3 nuts. Torque:
Bolt A: 52 N
m (530 kgf
cm, 38 ft
lbf)
Bolt B: 96 N
m (979 kgf
cm, 71 ft
lbf)
(e)w/ HID: Connect the height control sensor (Front) connector.
16.INSTALL FRONT SUSPENSION ME MBER BRACE
REAR LH
(a)Install the front suspension member body mounting stop- per rear to the front suspension member brace rear LH.
(b)Install the 4 bolts and front suspension member brace rear LH.
Torque:
Bolt A: 80 N
m (816 kgf
cm, 59 ft
lbf)
Bolt B: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
17.INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
18.CONNECT RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36

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.

270E4±01
G23906
G25775
G23871

G25777
27±24
±
REAR SUSPENSION LOWER CONTROL ARM ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
LOWER CONTROL ARM ASSY LH
REPLACEMENT
HINT:
COMPONENTS: See page 27±2.
1. REMOVE REAR WHEEL 2. REMOVE LOWER CONTROL ARM ASSY LH
(a) RH side (w/ Height control sensor):Remove the nut, and separate the height control sensor
sub±assy from the lower control arm assy RH.
(b) Support the rear suspension arm assy No.1 LH.
(c) Remove the bolt, and separate the member side lower control arm assy LH.
(d) Remove the clip and nut.

G23871
G23906
27±26
±
REAR SUSPENSION LOWER CONTROL ARM ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
7. FULLY TIGHTEN LOWER CONTROL ARM ASSY LH
(a) Fully tighten the bolt. Torque: 105 N
m (1,071 kgf
cm, 77 ft
lbf)
(b) RH side (w/ Height control sensor): Install the height control sensor sub±assy and nut to the
lower control arm assy RH.
Torque: 5.8 N
m (59 kgf
cm, 51 in.
lbf)
(c) RH side (w/ Height control sensor): Headlight aim only (See page 65±19).
8.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)