TOYOTA AVENSIS 2002 Repair Manual

330C6±01
F44810
F41838
F44811
F44812
33±4
±
PARKING BRAKE PARKING BRAKE LEVER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) (See page 41±11)
2.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY LOWER (See page 71±11)
4.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
5. REMOVE PARKING BRAKE LEVER SUB±ASSY
(a) Disconnect the parking brake switch connector from theparking brake switch.
(b) Remove the lock nut and adjusting nut from the parking brake cable assy No.1.
(c) Remove the 2 bolts.
(d) Using a screwdriver, raise the pick on the parking brake lever, and remove the parking brake cable assy No.1 from
the parking brake lever.
(e) Remove the parking brake lever from the body.
6. REMOVE PARKING BRAKE SWITCH ASSY
(a) Remove the screw and parking brake switch.

F44812
F44813
F41838
F44810
±
PARKING BRAKE PARKING BRAKE LEVER SUB±ASSY
33±5
AVENSIS REPAIR MANUAL (RM1018E)
7. INSTALL PARKING BRAKE SWITCH ASSY
(a) Install the parking brake switch to the parking brake lever
with the screw.
8. INSTALL PARKING BRAKE LEVER SUB±ASSY
(a) Install the parking brake cable assy No.1 to the parking brake lever, temporally tighten the adjusting nut and lock
nut.
(b) Using a screwdriver, fix the parking brake cable No.1 to the pick.
(c) Install the parking brake lever with the 2 bolts. Torque: 13 N
m (127 kgf
cm, 9 ft
lbf)
(d) Install the parking brake switch connector to the parking brake switch.
9.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
10.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)

3300E±07
±
PARKING BRAKE PARKING BRAKE SYSTEM
33±1
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the likelihood of the
cause in the descending order. Check each parts in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Brake drag
1. Parking brake lever travel (Out of adjustment)
2. Parking brake wire (Sticking)
3. Parking brake shoe clearance (Out of adjustment)
4. Parking brake shoe lining (Cracked or distorted)
5. Tension or return spring (Damaged)33±2
33±7
33±10
33±14
33±14
33±14

3300F±07
F44808
Lock NutAdjusting Nut
33±2
±
PARKING BRAKE PARKING BRAKE SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. REMOVE REAR WHEEL
2.ADJUST PARKING BRAKE SHOE CLEARANCE (See page 33±14)
3. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
4. INSPECT PARKING BRAKE LEVER TRAVEL
(a) Pull the parking brake lever all the way up, and count the number of cli\
cks. Parking brake lever travel: 6 ± 9 clicks at 196 N (20 kgf, 44.1 lbf)\
5. ADJUST PARKING BRAKE LEVER TRAVEL
(a) Remove the console box assy RR.(See page71±11)
(b) Loosen the lock nut and turn the adjusting nut until the le- ver travel turns correct.
(c) Tighten the lock nut. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(d) Install the console box assy RR.
(See page 71±11)

5100F±06
±
POWER STEERING POWER STEERING SYSTEM
51±1
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING SYSTEM
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Care must be taken to replace parts properly because they could affect the performance of the steering
system and result in a driving hazard.
2. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as \
the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence \
could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious acc\
ident. Before servicing (in-
cluding removal or installation of parts, inspection or replacement), be sure \
to read the precautionary
notices in the supplemental restraint system (See page 60±1).

5100G±06
51±2
±
POWER STEERING POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help you find the cause of the problem. The numbers \
indicate the likelihood of the
cause in the descending order. Check each part in the order shown. Replace parts if necessary.
Hydraulic Power Steering System:
SymptomSuspect AreaSee page
Hard steering
3. Tires (Improperly inflated)
4. Power steering fluid level (Low)
5. Drive belt (Loose)
6. Front wheel alignment (Incorrect)
7. Steering system joints (Worn)
8. Suspension arm ball joints (Worn)
9. Steering column (Binding)
10.Power steering vane pump AZ Series: 1CD±FTV:
11. Power steering gear28±1
51±4
26±6 ±
26±24 ±
51±9
51±19 51±4
51±36
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gear28±1
26±6 ±
51±4
51±36
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear±
26±24 ±
30±2
51±4
51±36
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering vane pump AZ Series: 1CD±FTV:
4. Power steering gear51±4
±
51±9
51±19 51±4
51±36

±
POWER STEERING POWER STEERING SYSTEM
51±3
AVENSIS REPAIR MANUAL (RM1018E)
Electronic Power Steering System:
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering system joints (Worn)
4. Suspension arm ball joints (Worn)
5. Steering column (Binding)
6. Steering column (Electric power steering system)
7. Steering gear (torque)28±1
26±6
±
26±24 ±
50±9
51±28
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Steering column (Electric power steering system)
5. Steering gear (torque)28±1
26±6 ±
50±9
51±28
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Steering column (Electric power steering system)
6. Steering gear (torque)±
26±24 ±
30±2
50±9
51±28
Abnormal noise
1. Steering system joints (Worn)
2. Steering column (Electric power steering system)
3. Steering gear (torque)±
50±9
51±28
HINT:
When the problem occurs on the Electric Power Steering system, refer to \
the DI section (See page 05±1042
).

510DE±02
F40449
R11229
Normal
Abnormal
R00427
51±4
± POWER STEERINGPOWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords,
etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
missing chunks from the ribs are found on the belt, it should be
replaced.
2. BLEED POWER STEERING SYSTEM
(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with the
stands.
(c) Turn the steering wheel.
(1) With the engine stopped, turn the wheel slowly from
lock to lock several times.
(d) Lower the vehicle.
(e) Start the engine.
(1) Run the engine at idle for a few minutes.
(f) Turn the steering wheel.
(1) With the engine idling, turn the wheel to right full lock
position and keep it there for 2 to 3 seconds, then
turn the wheel to left full lock position and keep it
there for 2 to 3 seconds.
(2) Repeat (1) several times.
(g) Stop the engine.
(h) Check for foaming or emulsification.
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
(i) Recheck the fluid level.
3. 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:
If the fluidis hot, check that the fluid level is within the HOT LEV-
EL range on the oil reservoir. If the fluid is cold, check that it is
within the COLD LEVEL range.

R11229
NormalAbnormal
R11786Engine Idling Engine Stopped5 mm (0.20 in.)
or less
±
POWER STEERING POWER STEERING SYSTEM
51±5
AVENSIS REPAIR MANUAL (RM1018E)
(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 the power steering
system.
(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.
(i) Check the fluid level.
4. CHECK STEERING FLUID PRESSURE
(a) AZ Series: Disconnect the pressure feed tube assy from the vane
pump assy (See page 51±9).
(b) 1CD±FTV: Disconnect the pressure feed tube assy from the vane
pump assy (See page 51±19).
(c) AZ Series: Connect SST(s), as shown in the illustration on the next
page.
SST 09640±10010 (09641±01010, 09641±01030, 09641±01060)
NOTICE:
Check that the valve of SST(s) is in the open position.
(d) 1CD±FTV: Connect SST(s), as shown in the illustration on the next
page.
SST 09640±10010 (09641±01010, 09641±01020, 09641±01030)
NOTICE:
Check that the valve of SST(s) is in the open position.
(e) Bleed the power steering system.
(f) Start the engine and run it at idle.
(g) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80
C (176
F)

D30364
Attachment
OUT
IN IN OUTAttachment
SST(s) SST(s)
Attachment
Attachment AZ Series:
1CD±FTV:
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST(s) Closed
Z15499
Oil
Reservoir
PS Vane
Pump PS Gear
SST(s) Open 51±6
± POWER STEERINGPOWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(h) With the engine idling, close the valve of SST(s) and ob-
serve the reading on SST(s).
Minimum fluid pressure:
AZ Series:
8,300 to 9,000 kPa (85 to 92 kgf/cm
2, 1,204 to 1,305 psi)
1CD±FTV:
8,800 to 9,500 kPa (90 to 97 kgf/cm
2, 1,276 to 1,378 psi)
NOTICE:

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

Do not let the fluid temperature become too high.
(i) With the engine idling, open the valve fully.
(j) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Fluid pressure difference:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.