TOYOTA AVENSIS 2003 Service Repair Manual

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
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F40259
Matchmarks
C80324
F40049
SST(s)
Vinyl Tape
F40050
Matchmarks
±
POWER STEERING STEERING 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.
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ZK8184
F40083
F40052
SST(s)
SST(s) Hold
Turn
F40051
SST(s)
51±30
±
POWER STEERING STEERING 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 usinganother 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.
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F40053
SST(s)
SST(s)
Fulcrum
LengthHold
Turn
C57755
F400843 mm (0.12 in.) or less SST(s)
±
POWER STEERING STEERING 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 shownin 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.
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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)
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±
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)
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5106Z±04
D30360


12 (122, 9)Flow Control Valve
Compression SpringPower Steering Suction Port Union
Vane Pump Housing Oil Seal


Vane Pump
Shaft Snap Ring
Vane Pump Side Plate Front
Vane Pump Rotor
Vane Pump Plate
Vane Pump Cam Ring
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Power steering fluid






22 (224, 16)
 10
Pressure Port Union
Sub±assy
Flow Control Valve Assy
Vane Pump Housing
Sub±assy Front


Vane Pump Housing
Sub±assy Rear
69 (704, 51)
O±ringO±ring
O±ring
O±ring
w/pulley Shaft Sub±assy
51±18
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
VANE PUMP ASSY (1CD±FTV)
COMPONENTS
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510DH±02
D30579SST(s)
D30580
C84636
SST(s)
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
51±19
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
NOTICE:

When using a vise, do not overtighten.

When installing, coat the parts indicated by the arrows with power steer\
ing fluid
(See page 51±18).
1. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
2. REMOVE ENGINE COVER NO.1
(a) Remove the bolt, 4 nuts and the engine cover No. 1.
3. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Remove the clip and disconnect the oil reservoir to pump hose No. 1.
NOTICE:
Take care not to spill fluid on the V belt.
4. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Remove the bolt and sepatate the tube clamp.
(b) Using SST(s), disconnect the pressure feed tube assyfrom the vane pump assy.
SST 09023±12700
5. REMOVE VANE PUMP ASSY
(a) Remove the 4 bolts, the vane pump assy and the vane pump bracket rear.
6. FIX VANE PUMP ASSY
(a) Using SST(s), hold the vane pump assy in a vise. SST 09630±00014 (09631±00132)
7. REMOVE POWER STEERING SUCTION PORT UNION
(a) Remove the bolt and the suction port union.
(b) Remove the O±ring from the suction port union.
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D30361
C84483
C57767
C65368
51±20
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE FLOW CONTROL VALVE ASSY
(a) Remove the pressure port union sub±assy.
(b) Remove the O±ring from the pressure port union sub± assy.
(c) Remove the flow control valve assy and the compression spring.
9. REMOVE VANE PUMP HOUSING SUB±ASSY REAR
(a) Remove the 4 bolts and housing sub±assy rear from the housing sub±assy front.
(b) Remove the O±ring from the housing sub±assy rear.
10. REMOVE W/PULLEY SHAFT SUB±ASSY
(a) Using 2 screwdrivers, remove the snap ring from the w/ pulley shaft sub±assy.
(b) Remove the w/pulley shaft sub±assy.
11. REMOVE VANE PUMP ROTOR
(a) Remove the 10 vane pump plates.
(b) Remove the vane pump rotor.
12. REMOVE VANE PUMP CAM RING 13. REMOVE VANE PUMP SIDE PLATE FRONT
(a) Remove the side plate front from the housing sub±assyfront.
(b) Remove the O±ring from the side plate front.
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C65369
D30331
Cloth
F09875


D30332
LengthThickness
R10282
Feeler Gauge
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
51±21
AVENSIS REPAIR MANUAL (RM1018E)
(c) Remove the O±ring from the housing sub±assy front.
14. REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using a screwdriver, remove the housing oil seal.
NOTICE:
Be careful not to damage the pump housing.
15. INSPECT VANE PUMP SHAFT AND BUSH IN
HOUSING FRONT
(a) Using a micrometer and a caliper gauge, measure the oil clearance.
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the vane pump assy.
16. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES
(a) Using a micrometer, measure the thickness of the vane pump plates.
Minimum thickness:
1.405 to 1.411 mm (0.05531 to 0.05555 in.)
(b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and vane plate.
Maximum clearance: 0.03 mm (0.0012 in.)
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