oil TOYOTA AVENSIS 1999 Supplement

BR11P–01
F08963
Vacuum Hose
Oil Hose
– BRAKEVACUUM PUMP (1CD–FTV)
BR–3
REMOVAL
1. DISCONNECT 2 VACUUM HOSES AND OIL HOSE
FROM VACUUM PUMP
2. REMOVE VACUUM PUMP
(a) Remove the 2 bolts and vacuum pump.
(b) Remove the 2 O–rings from the vacuum pump.

BR11S–01
F08980
F08981
F08982
New O–Ring
F08970
F08969
– BRAKEVACUUM PUMP (1CD–FTV)
BR–7
REASSEMBLY
1. INSTALL COUPLING
(a) Place the coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
2. INSTALL ROTOR INTO CASING
Coat the rotor with engine oil, and install it to the rotor shaft.
3. INSTALL 5 BLADES
(a) Coat the 5 blades with engine oil.
(b) Install the 5 blades with the round end facing outward.
HINT:
Be sure that the blades and rotor surfaces are even.
4. INSTALL END COVER
(a) Coat 2 new O–rings with engine oil, and place them to the
casing.
(b) Place the vacuum pump on the vise, as shown in the il-
lustration.
NOTICE:
Do not tighten the vise.
(c) Place the end cover, and temporarily install the 3 bolts.
(d) Using a pin punch and hammer, drive in the 2 straight
pins.
(e) Using soft jaws on the vise, place the vacuum pump in the
vise.
NOTICE:
Do not tighten the vise too tightly.
(f) Tighten the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

BR11T–01


F08964
New O–RingVacuum Hose
Oil Hose
– BRAKEVACUUM PUMP (1CD–FTV)
BR–9
INSTALLATION
1. INSTALL VACUUM PUMP
(a) Coat 2 new O–rings with engine oil, and install them to the
vacuum pump.
(b) Insert the vacuum pump, align the coupling with slit of the
camshaft.
(c) Install the 2 bolts.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
2. CONNECT 2 VACUUM HOSES AND OIL HOSE

F03737
4A–FE and 7A–FE Engines
2C–T, 2C–TE, 3S–FE and 1CD–FTV
EnginesSR0I8–02
R07281
Normal
Abnormal
R10552Engine IdlingEngine Stopped 5 mm (0.20 in.) or less
– STEERINGPOWER STEERING FLUID
SR–3
POWER STEERING FLUID
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir / reservoir cap dipstick.
If the fluid is cold, check that it is within the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80
C (176
F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem (See Pub. No. RM599E on page SR–5).
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system (See Pub.
No. RM599E on page SR–5).
(i) Check the fluid level.

Z15498
Oil
reservoir
PS Vane
Pump
SST Closed PS Gear
Z15499
Oil
reservoir
PS Vane
Pump
SST Open Lock Position
PS Gear
Z15500
Oil
reservoir
PS Vane
Pump PS Gear
SST Open Lock Position
– STEERINGPOWER STEERING FLUID
SR–5
(f) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Minimum fluid pressure:
4A–FE and 7A–FE engines8,238 kPa (84 kgf/cm2, 1,195 psi)
3S–FE engine9,022 kPa (92 kgf/cm2, 1,309 psi)
2C–T, 2C–TE and 1CD–FTV engines8,826 kPa (90 kgf/cm2, 1,280 psi)
NOTICE:

Do not keep the valve closed for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(g) With the engine idling, open the valve fully.
(h) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Difference fluid pressure:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
(i) With the engine idling and valve fully opened, turn the
steering wheel to full lock.
Minimum fluid pressure:
4A–FE and 7A–FE engines8,238 kPa (84 kgf/cm2, 1,195 psi)
3S–FE engine9,022 kPa (92 kgf/cm2, 1,309 psi)
2C–T, 2C–TE and 1CD–FTV engines8,826 kPa (90 kgf/cm2, 1,280 psi)
NOTICE:

Do not maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(j) Disconnect the SST.
(k) Connect the pressure feed tube to PS vane pump
[See Pub. No. RM599E on page SR–22 (4A–FE and 7A–
FE engines), SR–25 (3S–FE engine), and see page
SR–16 (2C–T, 2C–TE and 1CD–FTV engine)].
(l) Bleed the power steering system(See Pub. No. RM599E
on page SR–5).

F03716
N·m (kgf·cm, ft·lbf): Specified torque
 Non–reusable partPressure Port Union
 Shorter Straight Pin
 O–Ring  Snap Ring  O–Ring
 Longer Straight PinSide Front Plate
Flow Control Valve
Spring
 Oil Seal
Front HousingSuction Port UnionVane Pump
Shaft
Power steering fluid
69 (700, 51)
13 (130, 9)
 O–Ring
 O–Ring
 O–Ring  Snap Ring
Cam Ring
Rear Housing
Wave Washer  O–Ring
Side Rear Plate Vane Pump RotorVane Plate
x10
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–7

SR0WD–01
F03717
F03718
F03719
Vinyl Tape
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–9
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Temporarily install the vane pump pulley set nut.
(c) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE SUCTION PORT UNION
(a) Remove the bolt and suction port union.
(b) Remove the O–ring from the union.
3. REMOVE PRESSURE PORT UNION
(a) Remove the pressure port union.
(b) Remove the O–ring from the union.
4. REMOVE FLOW CONTROL VALVE AND SPRING
5. REMOVE REAR HOUSING, WAVE WASHER AND SIDE
REAR PLATE
(a) Using 2 screwdrivers, remove the snap ring.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the vane pump shaft.
(c) Using a plastic hammer, tap out the rear housing, wave
washer and side rear plate.
(d) Remove the O–ring from the rear housing.
(e) Remove the O–ring from the side rear plate.
6. REMOVE CAM RING AND 10 VANE PLATES
NOTICE:
Be careful not to drop the plate.
7. REMOVE VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
8. REMOVE VANE PUMP ROTOR AND SIDE FRONT
PLATE
(a) Using a screwdriver, remove the snap ring from the vane
pump shaft.
(b) Remove the vane pump rotor and side front plate.
(c) Remove the 2 O–rings from the side front plate.
9. REMOVE SHORTER STRAIGHT PIN
Using pliers, remove the shorter straight pin from the side front
plate.

F01876
Bushing
Front
Housing Vane Pump
Shaft
SR0WE–01
Z06061
Thickness
Height
Length
R10282
Feeler Gauge
F01319
Inscribed Mark
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–11
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.01 – 0.03 mm (0.0004 – 0.0012 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.1 mm (0.319 in.)
Minimum thickness: 1.797 mm (0.0708 in.)
Minimum length: 14.988 mm (0.5901 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with the one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None

R08702
F01345
Vinyl Tape
F01317
Press
Oil Seal SST
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–13
4. INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 36.0 mm (1.417 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver with vinyl tape wound around its tip,
remove the oil seal.
NOTICE:
Be careful not to damage the front housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST and a press, press in the oil seal.
SST 09950–60010 (09951–00310),
09950–70010 (09951–07100)
NOTICE:
Make sure to install the oil seal facing the correct direction.

SR0WF–01
Z13635
Inscribed Mark
F03721
Longer
Straight Pin
Hole
F01314
Inscribed Mark
SR–14– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID (See page SR–6)
2. INSTALL LONGER STRAIGHT PIN
Using a plastic hammer, tap in a new longer straight pin to the
front housing.
NOTICE:
Be careful not to damage the pin.
3. INSTALL SHORTER STRAIGHT PIN
Install a new short straight pin to the side front plate.
NOTICE:
Be careful not to damage the pin.
4. INSTALL SIDE FRONT PLATE AND VANE PUMP RO-
TOR
(a) Coat 2 new O–rings with power steering fluid and install
them to the side front plate.
(b) Install the plate to the pump shaft.
NOTICE:
Make sure to install the plate facing the correct direction.
(c) Install the vane pump rotor to the pump shaft with the in-
scribed mark facing outward.
(d) Install a new snap ring to the vane pump shaft.
5. INSTALL VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
Align the hole of the side front plate and longer straight pin, and
tap in the shaft with a plastic hammer.
NOTICE:
Be careful not to damage the oil seal and O–rings.
6. INSTALL CAM RING
Align the holes of the cam ring and 2 straight pins and install the
ring with the inscribed mark facing outward.