TOYOTA AVENSIS 2002 Repair Manual

C94598
C94596
A
BB
B
LH:
C94597
A
BB
B
RH:
C94595
D29969
A
B
A
B
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51±43
AVENSIS REPAIR MANUAL (RM1018E)
43. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Using a transmission jack, support the crossmember
sub±assy w/power steering gear assy.
(b) Install the 2 stopper front onto the crossmember sub±
assy.
(c) Install the crossmember sub±assy with the 2 nuts.
Torque: 133 N
m (1,356 kgf
cm, 98 ft
lbf)
(d) Install the stopper rear onto the crossmember bracket LH.
(e) Install the crossmember bracket LH with the 4 bolts.
Torque:
Bolt A: 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B: 80 N
m (816 kgf
cm, 59 ft
lbf)
(f) Install the stopper rear onto the crossmember bracket
RH.
(g) Install the crossmember bracket RH with the 4 bolts.
Torque:
Bolt A: 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B: 80 N
m (816 kgf
cm, 59 ft
lbf)
(h) Install the engine mounting insulator RR to the cross-
member sub±assy with the bolt and the 3 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
(i) Install the center member with the 4 bolts.
Torque:
Bolt A: 45 N
m (459 kgf
cm, 33 ft
lbf)
Bolt B: 52 N
m (530 kgf
cm, 38 ft
lbf)

D29968
RHD:
LHD:
Fulcrum Length
Fulcrum Length
SST(s)
SST(s)
D29967
RHD:
LHD:
Fulcrum LengthFulcrum
Length
SST(s)
SST(s)
51±44
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
44.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
45. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
46.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
47. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side. 48. CONNECT PRESSURE FEED TUBE ASSY
(a) Using SST(s), connect the pressure feed tube assy.SST 09023±12700
Torque: 41 N
m (414 kgf
cm, 30 ft
lbf)
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).

This torque value is effective when SST(s) is parallel to a
torque wrench.
49. CONNECT STEERING GEAR OUTLET RETURN TUBE
(a) Using SST(s), connect the outlet return tube. SST 09023±12700
Torque: 41 N
m (414 kgf
cm, 30 ft
lbf)
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).

This torque value is effective when SST(s) is parallel to a
torque wrench.
(b) LHD: Install the tube clamp with bolt to the power steering gear
assy.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)



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)

510DI±02
D30014
Stopper
Front
133 (1,356, 98)
89 (908, 66)
Front Stabilizer
Link Assy RH
74 (755, 55)
133 (1,356, 98)
80 (816, 59)
Stopper Rear
80 (816, 59)
52 (530, 38)
45 (459, 33)Center Member
52 (530, 38)
133 (1,356, 98)
Stopper Front
89 (908, 66)
80 (816, 59)
133 (1,356, 98)
80 (816, 59)
Stopper Rear
Crossmember
Bracket LH
74 (755, 55)
Front Stabilizer Link Assy LH
Front Suspension
Crossmember Sub±assy
Clip
Steering Intermediate Shaft
Assy No.2
35 (360, 26)
Steering Intermediate Shaft
Steering Column Hole
Cover Sub±assy No.1
Tie Rod End
Sub±assy RH
49 (500, 36)
74 (750, 54)
Lock Nut
Steering Rack
Boot Clip
Steering Rack
Boot No.1
49 (500, 36)
Steering Rack Boot
No.1 Clamp

Steering Rack
End Sub±assy
Lock Nut
Steering Rack Boot
No.2 Clamp

Steering Rack
Boot No.2
Steering Rack
Boot Clip
Tie Rod End
Sub±assy LH
49 (500, 36)

Cotter Pin
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part
Slicon grease
Engine Under Cover LH
Column Hole Cover
Silencer Sheet
Molybdenum disulfide lithium base grease
49 (500, 36)
49 (500, 36)
* For use with SST(s)
83.5 (851, 62)
*60 (616, 45)
74 (750, 54)
± POWER STEERINGSTEERING GEAR ASSY
51±27
AVENSIS REPAIR MANUAL (RM1018E)
STEERING GEAR ASSY
COMPONENTS

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

F40259
Matchmarks
C80324
F40049
SST(s)
Vinyl Tape
F40050
Matchmarks
± POWER STEERINGSTEERING GEAR ASSY
51±29
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the intermediate shaft and the pin-
ion shaft.
(b) Remove the bolt and the steering intermediate shaft.
21. REMOVE STEERING GEAR ASSY
(a) Remove the 4 bolts, the 4 nuts and the steering gear assy
from the crossmember sub±assy.
NOTICE:
Because the nut has its own stopper, do not turn the nut
and torque the bolt with the nut fixed.
22. FIX STEERING GEAR ASSY
(a) Using SST(s), secure the steering gear assy in a vise.
SST 09612±00012
HINT:
Tape the SST(s) before use.
23. REMOVE TIE ROD END SUB±ASSY LH
(a) Place matchmarks on the tie rod end sub±assy and the
rack end sub±assy.
(b) Loosen the lock nut and remove the tie rod end sub±assy
and the lock nut.
24. REMOVE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.

ZK8184
F40083
F40052
SST(s)
SST(s)Hold
Turn
F40051
SST(s) 51±30
± POWER STEERINGSTEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
25. INSPECT TIE ROD END SUB±ASSY LH
(a) Secure the tie rod end sub±assy in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torx wrench, turn the nut continuously at a rate of
2 to 4 seconds per turn and take the torque reading on the
5th turn.
Turning torque:
0.29 to 1.96 N
m (3 to 20 kgf
cm, 2.57 to 17.35 in.
lbf)
26. INSPECT TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
27. REMOVE STEERING RACK BOOT CLIP
(a) Using a pliers, remove the 2 boot clips from each rack boots.
28. REMOVE STEERING RACK BOOT NO.2 CLAMP
(a) Using a screwdriver, unstake the rack boot No.2 clamp.
NOTICE:
Be careful not to damage the boot.
29. REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT:
Perform the same procedure on the other side.
30. REMOVE STEERING RACK BOOT NO.2
31. REMOVE STEERING RACK BOOT NO.1
32. REMOVE STEERING RACK END SUB±ASSY
(a) Using SST(s), hold the steering rack steadily and using
another SST(s), remove the rack end sub±assy.
SST 09922±10010
NOTICE:
Use SST(s) 09922±10010 in the direction shown in the il-
lustration.
HINT:
Perform the same procedure on the other side.
33. INSPECT TOTAL PRELOAD
(a) Temporarily install the RH and LH rack end sub±assy.
(b) Using SST(s) and a torque wrench, check the preload.
SST 09616±00011
Preload (turning):
0.6 to 1.1 N
m (6 to 11 kgf
cm, 5.3 to 9.7 in.
lbf)
If it is not within specification, replace the steering gear assy.

F40053
SST(s)
SST(s)
Fulcrum
Length
Hold
Turn
C57755
F400843 mm (0.12 in.) or lessSST(s)
± POWER STEERINGSTEERING GEAR ASSY
51±31
AVENSIS REPAIR MANUAL (RM1018E)
34. INSTALL STEERING RACK END SUB±ASSY
(a) Using SST(s), hold the steering rack steadily and using
another SST(s), torque the rack end sub±assy.
SST 09922±10010
Torque: 60 N
m (616 kgf
cm, 45 ft
lbf)
NOTICE:
Use SST(s) 09922±10010 in the direction shown in the il-
lustration.
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.)

Perform the same procedure on the other side.
35. INSTALL STEERING RACK BOOT NO.2
(a) Apply silicon grease to the inside small caliber of rack
boot No.2.
(b) Install the rack boot No.2 to the groove on the rack hous-
ing.
NOTICE:
Be careful not to damage or twist the boot.
36. INSTALL STEERING RACK BOOT NO.1
HINT:
Perform the same procedure on the other side.
37. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Install a new rack boot No.2 clamp to the rack boot No.2.
(b) Using SST(s), stake the rack boot No.2 clamp as shown
in the illustration.
SST 09521±24010
38. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09521±24010
HINT:
Perform the same procedure on the other side.

D30584
SST(s)
F40050
Matchmarks
C80324
F40259
Matchmarks
51±32
±
POWER STEERING STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL STEERING RACK BOOT CLIP
(a) Using a pliers, install the 2 rack boot clips to each rack boots.
(b) Using SST(s), check that the rack boot No.2 is strechy. SST 09616±00011
40. INSTALL TIE ROD END SUB±ASSY LH
(a) Screw the lock nut and the tie rod end sub±assy to the rack end sub±assy until the matchmarks are aligned.
Torque: 74 N
m (750 kgf
cm, 54 ft
lbf)
HINT:
After adjusting toe±in, torque the lock nut
(See page 26±6).
41. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side. 42. INSTALL STEERING GEAR ASSY
(a) Install the steering gear assy onto the crossmember sub±assy with the 4 bolts and the nuts.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
NOTICE:
Because the nut has its own stopper, do not turn the nut
and torque the bolt with the nut fixed.
43. INSTALL STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the steering intermediate shaft and the steering pinion shaft.
(b) Install the bolt. Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
44. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
45.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 51±36)

±
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)