TOYOTA AVENSIS 2002 Owners Manual

32092±05
G24249
Oil Hose
Vacuum HoseO±Ring
Vacuum Pump Assy
Vacuum Hose
Check Valve Sub±assy
Vacuum Pump Union Gasket
Straight Pin
Vacuum Pump End Cover Snap Ring
CouplingVaccup Pump Housing
Vacuum pump Blade A
Straight Pin
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part

O±Ring



Gasket

Gasket


O±Ring

Union bolt
7.8 (80, 69 in.
lbf)
7.8 (80, 69 in.
lbf)
7.8 (80, 69 in.
lbf)
14 (140, 10)
21 (214, 15)
21 (214, 15)
Air Cleaner Cap Sub±assy
74 (750, 54)
Connector
Vacuum pump Rotor
32±34
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

320W2±01
G24251
Vacuum Hose
Oil Hose
F45364
F08966
F08967
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±35
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
1. REMOVE AIR CLEANER CAP SUB±ASSY
2. REMOVE VACUUM PUMP ASSY
(a) Disconnect the 2 vacuum hoses and oil hose from the
vacuum pump assy.
(b) Remove the 2 bolts and vacuum pump assy.
(c) Remove the 2 O±rings from the vacuum pump assy.
3. INSPECT VACUUM PUMP ASSY
(a) Turn the coupling counterclockwise direction by hand
when seeing from the coupling direction and check for
any abnormality such as dragging or torque fluctuation.
NOTICE:
Pay coupling attention, because the engine oil remained in
the pump escapes while coupling is turning.
4. REMOVE VACUUM PUMP UNION
(a) Using soft jaws on a vise, hold the vacuum pump assy in
a vise.
NOTICE:
Do not tighten the vise excessively and perform the work
while holding the vacuum pump assy by hand.
(b) Remove the union bolt, vacuum pump union and 2 gas-
kets.
5. REMOVE CHECK VALVE SUB±ASSY
(a) Remove the check valve sub±assy and gasket.

F08969
F08970
F08971
F08972
Snap Ring
F45365
Vacuum Pump Housing
Vacuum Pump End Cover
32±36
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE VACUUM PUMP ROTOR SUB±ASSY
(a) Remove the 3 bolts.
(b) Using soft jaws on the vise, place the vacuum pump assy
on the vise, as shown in the illustration.
NOTICE:
Only place the vacuum pump assy, never hold the in±low
of the housing with a vise.
(c) Using a pin punch and hammer, drive out the 2 straight
pins.
(d) Remove the end cover and 2 O±rings.
(e) Remove the vacuum pump rotor and 5 blades.
NOTICE:
Do not damage the housing with the rotor.
7. REMOVE VACUUM PUMP COUPLING
(a) Using a screwdriver, remove the snap ring.
(b) Remove the coupling.
8. INSPECT VACUUM PUMP HOUSING
(a) Inspect the inside surface on the housing for scoring.
If necessary, replace the vacuum pump assy.
9. INSPECT VACUUM PUMP END COVER
(a) Inspect the inside surface on the vacuum pump end cover
for scoring.
If necessary, replace the vacuum pump assy.

F05383
Air
Hose Side Vacuum Pump Side
Air
F08981
F08982
New O±Ring
F08970
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±37
AVENSIS REPAIR MANUAL (RM1018E)
10. INSPECT CHECK VALVE SUB±ASSY
(a) Check that air flows from the hose side to the pump side.
(b) Check that air does not flow from the pump side to the
hose side.
NOTICE:
Block off the 4 holes on the side surface of the check valve
when checking.
If necessary, replace the check valve.
11. INSTALL VACUUM PUMP COUPLING
(a) Place the vacuum pump coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
12. INSTALL VACUUM PUMP ROTOR SUB±ASSY
(a) Coat the rotor with engine oil, and install it to the rotor shaft.
13. INSTALL VACUUM PUMP BLADE A
(a) Apply the engine oil to the rotor, and install the rotor in the
housing.
(b) Apply the engine oil to the 5 new blades.
(c) Install the 5 blades with the round end facing outward.
NOTICE:
Install so that the blade attaches on the housing.
(d) Coat 2 new O±rings with engine oil, and install them on
the housing.
(e) Using soft jaws on the vise, place the vacuum pump on
the vise, as shown in the illustration.
NOTICE:
Only place the vacuum pump assy, never hold the in±low
of the housing with a vise.
(f) Place the end cover, and temporarily install the 3 bolts.
(g) Using a pin punch and hammer, drive in the 2 straight
pins.
NOTICE:
Install so that the blade and end cover of the eccentric ring
does not interfere with each other.

F08969
F08984
New Gasket
F08985
New Gasket
New Gasket
F45364
32±38
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(h) Using soft jaws on the vise, hold the vacuum pump in the
vise.
NOTICE:
Do not tighten the vise to tightly.
(i) Tighten the 3 bolts.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
14. INSTALL CHECK VALVE SUB±ASSY
(a) Install the check valve sub±assy and a new gasket.
Torque: 74 N
m (750 kgf
cm, 54 ft
lbf)
15. INSTALL VACUUM PUMP UNION
(a) Install the vacuum pump union and 2 new gaskets with
the union bolt.
Torque: 14 N
m (140 kgf
cm, 10 ft
lbf)
HINT:
Align and insert the pin of the union into the matching hole of
the casing.
16. INSPECT VACUUM PUMP ASSY
(a) Turn the gear counterclockwise direction by hand when
seeing from the vacuum pump gear direction and check
for any abnormality such as dragging or torque fluctua-
tion.

G24250
Vacuum HoseNew O±Ring
Oil Hose
F45366
Vacuum Gauge
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±39
AVENSIS REPAIR MANUAL (RM1018E)
17. INSTALL VACUUM PUMP ASSY
(a) Coat 2 new O±rings with engine oil, and install them to the
vacuum pump assy.
(b) Install the vacuum pump assy aligning the coupling with
the slit of the camshaft.
(c) Install the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(d) Connect 2 vacuum hoses and oil hose.
18. INSPECT CHECK VACUUM PUMP OPERATION
(a) Slide the clip, then disconnect the vacuum hose from vac-
uum pump assy.
(b) Connect the hose of the vacuum gauge to the vacuum
pump assy.
(c) Block off another hose of the vacuum gauge with the hose
clamp No.2.
(d) Start the engine and warm it up for more than 2 minutes.
(e) With the engine idle, check the negative pressure of the
vacuum pump assy.
Standard: More than 650 mmHg (86.7 kPa).
(f) Remove the vacuum gauge from the vacuum pump assy.
(g) Connect the vacuum hose with the clip to the vacuum
pump assy.
19. INSTALL AIR CLEANER CAP SUB±ASSY

320GM±02
G23169
G23170
G23171
G23170
±
BRAKE YAWRATE SENSOR
32±63
AVENSIS REPAIR MANUAL (RM1018E)
YAWRATE SENSOR
REPLACEMENT
NOTICE:

Don't use the dropped or damaged yawrate sensor.

Free from the foreing matters between yawrate sensor braket and body.

Make sure the sensor direction.
1.REMOVE FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
2. REMOVE YAWRATE SENSOR BRACKET
(a) Remove the bolt and upper part of the yawrate sensorbracket.
3. REMOVE YAWRATE SENSOR
(a) Disconnect the yawrate sensor connector from the yaw- rate sensor.
(b) Remove the 2 bolts and the yawrate sensor with the yaw- rate sensor bracket from the body.
(c) Remove the 2 nuts and yawrate sensor from the yawrate sensor bracket.
4. INSTALL YAWRATE SENSOR
(a) Install the 2 nuts and yawrate sensor to the yawrate sen- sor bracket.
Torque: 6 N
m (61 ft
lbf, 53 in.
lbf)
(b) Install the 2 bolts and the yawrate sensor with the yawrate sensor bracket to the body.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
(c) Connect the yawrate sensor connector to the yawrate sensor.

G23169
32±64
±
BRAKE YAWRATE SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL YAWRATE SENSOR BRACKET
(a) Install the bolt and upper part og the yawrate sensor bracket.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
6.INSTALL FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
7.PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (See page 05±756)

320GM±02
G23169
G23170
G23171
G23170
±
BRAKE YAWRATE SENSOR
32±63
AVENSIS REPAIR MANUAL (RM1018E)
YAWRATE SENSOR
REPLACEMENT
NOTICE:

Don't use the dropped or damaged yawrate sensor.

Free from the foreing matters between yawrate sensor braket and body.

Make sure the sensor direction.
1.REMOVE FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
2. REMOVE YAWRATE SENSOR BRACKET
(a) Remove the bolt and upper part of the yawrate sensorbracket.
3. REMOVE YAWRATE SENSOR
(a) Disconnect the yawrate sensor connector from the yaw- rate sensor.
(b) Remove the 2 bolts and the yawrate sensor with the yaw- rate sensor bracket from the body.
(c) Remove the 2 nuts and yawrate sensor from the yawrate sensor bracket.
4. INSTALL YAWRATE SENSOR
(a) Install the 2 nuts and yawrate sensor to the yawrate sen- sor bracket.
Torque: 6 N
m (61 ft
lbf, 53 in.
lbf)
(b) Install the 2 bolts and the yawrate sensor with the yawrate sensor bracket to the body.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
(c) Connect the yawrate sensor connector to the yawrate sensor.

G23169
32±64
±
BRAKE YAWRATE SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL YAWRATE SENSOR BRACKET
(a) Install the bolt and upper part og the yawrate sensor bracket.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
6.INSTALL FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
7.PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (See page 05±756)