TOYOTA AVENSIS 2003 Service Repair Manual

D29965
RHD:
LHD:
SST(s)
SST(s)
D29966
RHD:
LHD:
SST(s)
SST(s)
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±37
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
11. DISCONNECT STEERING GEAR OUTLET RETURNTUBE
(a) Using SST(s), disconnect the outlet return tube. SST 09023±12700
(b) LHD: Remove the bolt and separate the tube clamp from the
power steering gear assy.
12. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Using SST(s), disconnect the pressure feed tube assy. SST 09023±12700
13.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
14. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.
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\b
D30389
AZ Series:1CD±FTV:
No.1 Engine Hanger
No.2 Engine Hanger
No.1 Engine Hanger
No.2 Engine Hanger
No.1 Engine
Hanger UPR
D29969
C94595
51±38
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
15.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
16. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
17. REMOVE HOOD SUB±ASSY
18. REMOVE CYLINDER HEAD COVER SUB±ASSY 19. SUSPEND ENGINE ASSEMBLY
(a) Install the 2 or 3 engine hangers with the bolts in the cor-rect direction.
Parts No. :
AZ Series:1CD±FTV:
No.1 Engine Hanger12281±2801012281±27050
No.1 Engine Hanger UPR±Yellow: 12284±27020
Black: 12284±27030
No.2 Engine Hanger12282±28010Yellow: 12282±27060Black: 12282±27070
Bolt91512±6102091642±81025
Torque:
AZ Series:
38 N
m (390 kgf
cm, 28 ft
lbf)
1CD±FTV:
37 N
m (375 kgf
cm, 27 ft
lbf)
(b) Attach the engine chain hoist to the engine hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other parts.
20. REMOVE FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Remove the 4 bolts and separate the center member.
(b) Remove the bolt and the 3 nuts, separate the engine mounting insulator RR from the crossmember sub±assy.
(c) Using a transmission jack, support the crossmember
sub±assy.
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C94596
LH:
C94597
RH:
C94598
D30593
Matchmarks
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±39
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove the 4 bolts and the crossmember bracket LH.
(e) Remove the stopper rear from the crossmember bracket
LH.
(f) Remove the 4 bolts and the crossmember bracket RH.
(g) Remove the stopper rear from the crossmember bracket RH.
(h) Remove the 2 nuts and the crossmember sub±assy w/ power steering gear assy.
(i) Remove the 2 stopper front from the crossmember sub± assy.
21. REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 22. REMOVE STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the intermediate shaft and the pin-ion shaft.
(b) Remove the bolt and the intermediate shaft.
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D30594
F40050
Matchmarks
ZK8184
F40083
51±40
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
23. REMOVE RACK & PINION POWER STEERING GEAR ASSY
(a) Remove the 4 bolts, the nuts and the power 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.
24. REMOVE TIE ROD END SUB±ASSY LH
(a) Place matchmarks on the tie rod end sub±assy and the rack end.
(b) Loosen the lock nut, and remove the tie rod end sub±assy and the lock nut.
25. REMOVE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side. 26. 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 of2 to 4 seconds per turn and take the torque reading on the
5th turn.
Turning torque:
0.49 to 3.43 N
m (5.0 to 35 kgf
cm, 4.34 to 30.38 in. lbf)
27. INSPECT TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
28. REMOVE STEERING RACK BOOT NO.2 CLAMP
(a) Using a screwdriver, remove the rack boot No.2 clamp.
NOTICE:
Be careful not to damage the boot.
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C57755
F400843 mm (0.12 in.) or less
SST(s)
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±41
AVENSIS REPAIR MANUAL (RM1018E)
29. REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT:
Perform the same procedure on the other side.
30. REMOVE STEERING RACK BOOT CLIP
HINT:
Perform the same procedure on the rack boot clamps.
31. REMOVE STEERING RACK BOOT NO.2
32. REMOVE STEERING RACK BOOT NO.1
33. INSTALL STEERING RACK BOOT NO.2
(a) Apply silicon grease to the inside small caliber of rackboot 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.
34. INSTALL STEERING RACK BOOT NO.1
HINT:
Perform the same procedure on the other side. 35. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Install a new rack boot No.2 clamp.
(b) Using SST(s), stake the rack boot No.2 clamp as shownin the illustration.
SST 09521±24010
36. INSTALL STEERING RACK BOOT NO.1 CLAMP SST 09521±24010
HINT:
Perform the same procedure on the other side.
37. INSTALL STEERING RACK BOOT CLIP
SST 09521±24010
HINT:
Perform the same procedure on the rack boot clamps.
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F41467
Matchmarks
D30594
D30593
Matchmarks
51±42
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
38. INSTALL TIE ROD END SUB±ASSY LH
(a) Screw the lock nut and the tie rod end sub±assy to the rack end 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).
39. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side. 40. INSTALL RACK & PINION POWER STEERING GEARASSY
(a) Install the power steering gear assy with the 4 bolts and the nuts.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
NOTICE:

The 4 bushings must be securely installed to the pow-
er steering gear assy.

When tightening the bolts for power steering gear, the
bushings should not be bitten in.

Because the nut has its own stopper, do not turn the
nut and torque the bolt with the nut fixed.
41. INSTALL STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the intermediate shaft with the pinion shaft.
(b) Install the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
42. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
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C94598
C94596
A
BB
B
LH:
C94597
A
BB
B
RH:
C94595
D29969
A
B
A
B
±
POWER STEERING RACK & 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)
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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)
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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)
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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 ShaftSteering 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 STEERING STEERING GEAR ASSY
51±27
AVENSIS REPAIR MANUAL (RM1018E)
STEERING GEAR ASSY
COMPONENTS
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