power steering fluid TOYOTA AVENSIS 2003 Service Owner's Manual (2234 Pages)

510DF±02
F42473
Power Steering
Suction Port UnionO±ring

w/pulley Shaft Sub±assy Vane Pump Side
Plate FrontVane Pump Cam Ring
10

Nm (kgf cm, ftlbf) : Specified torque
Non±reusable part

Power steering fluid
Pump Bracket Rear
Flow Control Valve Assy

Flow Control Valve
Compression Spring
44 (449, 32)
Vane Pump Housing
Sub±assy Rear Vane Pump Housing
Sub±assy Front

Vane Pump Rotor
Vane Pump Plate
22 (224, 16)
Vane Pump Housing
Oil Seal

Power Steering
Oil Pressure Switch
21 (214, 15)
69 (704, 51)
Vane Pump
Shaft Snap Ring
O±ring
O±ring
O±ring
22 (224, 16)
Pressure Port Union
Sub±assy
12 (122, 9)
51±8
±
POWER STEERING VANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
VANE PUMP ASSY (AZ Series)
COMPONENTS
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510DG±02
F40529
Turn
Hold
D30330
SST(s)
A
B
F40247
SST(s)
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±9
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
NOTICE:
When using a vise, do not over tighten.
When installing, coat the parts indicated by the arrows with power steer\
ing fluid
(See page 51±8).
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE FAN AND GENERATOR V BELT 1AZ±FE: (See page 14±105)
1AZ±FSE: (See page 14±185)
4. 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.
5. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Remove the bolt and separate the pressure feed tubeassy from the pump bracket rear.
(b) Using a spanner (27 mm) to hold the pressure port union, remove the union bolt and gasket.
6. REMOVE VANE PUMP ASSY
(a) Disconnect the connector from the oil pressure switch.
(b) Using SST(s) and a deep socket (14 mm), loosen the bolt A.
SST 09249±63010
(c) Remove the bolt B and vane pump assy.
7. FIX VANE PUMP ASSY
(a) Using SST(s), hold the vane pump assy in a vise. SST 09630±00014 (09631±00132)
8. REMOVE PUMP BRACKET REAR
(a) Remove the bolt and vane pump bracket rear.
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R10282
Feeler Gauge
D30362Inscribed Mark
F41493
F41622
Compressed Air
51±12
±
POWER STEERING VANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
(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.)
If it is more than the maximum, replace the vane pump plate
and/or vane pump rotor with the one having the same mark as
stamped on the cam ring. Inscribed mark: 0, 1, 2, 3 or 4
HINT:
There are 5 different marks for vane pump plate.
MarkPart numberLength mm (in.)
044345±0211012.001 to 12.003
(0.47247 to 0.47255)
144345±0212011.999 to 12.000
(0.47240 to 0.47244)
244345±0213011.997 to 11.998
(0.47232 to 0.47236)
344345±0214011.995 to 11.996
(0.47224 to 0.47228)
444345±0215011.993 to 11.994
(0.47216 to 0.47220)
20. INSPECT FLOW CONTROL VALVE ASSY
(a) Coat the flow control valve assy with power steering fluid and check that it falls smoothly into the flow control valve
hole by its own weight.
If necessary, replace the vane pump assy.
(b) Check the flow control valve assy for leakage. Close one of the holes and apply compressed air of 392 to 490 kPa
(4 to 5 kgf cm
2, 57 to 71 psi) into the opposite side hole,
and confirm that air does not come out from the end holes.
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D31004
Inscribed Mark
R08702
Vernier Calipers
F08480
SST(s)
Oil Seal
D30334
Vinyl Tape
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±13
AVENSIS REPAIR MANUAL (RM1018E)
If necessary, replace the flow control valve assy with the one
having the same letter as inscribed on the housing sub±assy
front.
Inscribed mark: A, B, C, D, E or F
HINT:
There are 6 different marks for flow control valve assy.
MarkPart number
A44330±05130
B44330±05140
C44330±05150
D44330±05160
E44330±05170
F44330±05180
21. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum free length: 36.9 mm ( 1.453 in.)
If it is less than the minimum, replace the compression spring.
22. INSPECT PRESSURE PORT UNION SUB±ASSY
(a) If the union seat in the pressure port union sub±assy is remarkably damaged, it may cause flui\
d leak- age. Replace the pressure port union sub±assy.
23. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new housing oil seal lip with power steering fluid.
(b) Using SST(s) and a press, install a new housing oil seal.SST 09950±60010 (09951±00280), 09950±70010
(09951±07100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
24. INSTALL W/PULLEY SHAFT SUB±ASSY
(a) Coat inside bushing surface of the housing sub±assy front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub±assy.
NOTICE:
Do not damage the oil seal lip.
HINT:
Tape the shaft before inserting.
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C65369
C65368
F08482
Housing
Sub±assy Front
Side Plate Front
F08483
Inscribed Mark
C95038
51±14
±
POWER STEERING VANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
25. INSTALL VANE PUMP SIDE PLATE FRONT
(a) Coat a new O±ring with power steering fluid and install it into the housing sub±assy front.
(b) Coat a new O±ring with power steering fluid and install it onto the side plate front.
(c) Align the dent of the side plate front with that of the hous- ing sub±assy front, and install the side plate front.
NOTICE:
Make sure that the side plate front is installed facing in the
correct direction.
26. INSTALL VANE PUMP CAM RING
(a) Align the dent of the cam ring with that of the side plate front, and install the cam ring with the inscribed mark fac-
ing upward.
27. INSTALL VANE PUMP ROTOR
(a) Install the vane pump rotor.
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D30335
Inward
Outward
D30336
C70126
C53369
Service Bolt
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±15
AVENSIS REPAIR MANUAL (RM1018E)
(b) Coat 10 vane pump plates with power steering fluid.
(c) Install the vane pump plates with the round end facing
outward.
28. INSTALL VANE PUMP SHAFT SNAP RING
(a) Using a screwdriver and a snap ring expander, install a new snap ring to the w/pulley shaft sub±assy.
29. INSTALL VANE PUMP HOUSING SUB±ASSY REAR
(a) Coat a new O±ring with power steering fluid and install it onto the housing sub±assy rear.
(b) Align the straight pin of the housing sub±assy rear with the dents of the cam ring, side plate front and housing
sub±assy front, and install the vane pump housing sub±
assy rear with the 4 bolts.
Torque: 22 N m (224 kgf cm, 16 ftlbf)
30. INSPECT PRELOAD
(a) Check that the pump rotates smoothly without abnormal noise.
(b) Temporarily install the service bolt.
Recommended service bolt:
Thread diameter: 10 mm (0.39 in.)
Thread pitch: 1.25 mm (0.0492 in.)
Bolt length: 50 mm (1.97 in.)
(c) Using a torque wrench, check the pump rotating torque. Rotating torque:
0.27 N m (2.8 kgf cm, 2.4 ft lbf) or less
If the rotating torque is not as specified, check the housing oil
seal.
31. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Coat a new O±ring with power steering fluid and install it to the oil\
pressure switch.
(b) Install the oil pressure switch onto the vane pump assy. Torque: 21 N m (214 kgf cm, 15 ftlbf)
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F42475
F40330
A
SST(s)
BFulcrum Length
F41596
Pressure Feed
Tube Assy
Stopper
51±16
±
POWER STEERING VANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
32. INSTALL FLOW CONTROL VALVE ASSY
(a) Coat the compression spring and the flow control valve assy with power steering fluid.
(b) Install the compression spring and the flow control valve assy.
(c) Coat a new O±ring with power steering fluid and install it onto the pressure port union sub±assy.
(d) Install the pressure port union sub±assy. Torque: 69 N m (704 kgf cm, 51 ftlbf)
33. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O±ring with power steering fluid, and install it to the su\
ction port union.
(b) Install the suction port union with the bolt. Torque: 12 N m (122 kgf cm, 9 ftlbf)
34. INSTALL PUMP BRACKET REAR
(a) Install the vane pump bracket rear with the bolt. Torque: 44 N m (449 kgf cm, 32 ftlbf)
HINT:
Make sure that the stopper of the bracket touches the vane pump body, then torque the bolt.
35. INSTALL VANE PUMP ASSY
(a) Temporarily tighten the bolt A to the vane pump assy.
(b) Install the vane pump assy and the bolt B.Torque: 37 N m (377 kgf cm, 27 ftlbf)
(c) Using SST(s) and a deep socket (14 mm), tighten the bolt
A.
SST 09249±63010
Torque: 26 N m (264 kgfcm, 19 ftlbf)
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.
(d) Connect the connector to the oil pressure switch.
36. CONNECT PRESSURE FEED TUBE ASSY
(a) Install the pressure feed tube assy and gasket to the vane pump assy with the union bolt.
HINT:
Make sure the stopper of the pressure feed tube assy touches
the pump housing front as shown in the illustration.
(b) Using a spanner (27 mm) to hold the pressure port union, torque the union bolt.
Torque: 52 N m (525 kgf cm, 38 ftlbf)
(c) Install the pressure feed tube assy with bolt to the pump bracket rear.
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
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±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±17
AVENSIS REPAIR MANUAL (RM1018E)
37. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No.1 with the clip.
NOTICE:
Take care not to spill fluid on the V belt.
38. INSTALL FAN AND GENERATOR V BELT
1AZ±FE: (See page 14±105)
1AZ±FSE: (See page 14±185)
39. INSTALL ENGINE UNDER COVER RH
40. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
41.ADD POWER STEERING FLUID (See page 51±4)
42.BLEED POWER STEERING FLUID (See page 51±4)
43.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
44. INSPECT FLUID LEAK
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338AVENSIS (EWD526E)
VSC
50A
VSC
4 50A
VSCFrom Power Source System
(
See Page 120 )
1 25A
VSC
4 25A
VSC
1 7. 5A
ECU–IG
DB
18
BG
C
CC C
AG
DC (
RHD )AG
(
LHD )
IE1
3
2
1
95 15
1
1
1 1
2222
IE1
22
14
EA 1
21 2
10 41 24 21 22
2
1
23 40
IB1
2IB1 1
R–W
R–W
L
( ∗ 1 )
L
( ∗ 2 )
R
( ∗ 1 )
R
( ∗ 2 )
R–W
R–W
B–Y
R–W
B–Y
R–W
L–Y
R–L W
B R
G
R
G
A 4A 5A32
J1 0 (
A )
, J11 (
B )
,
J2 0 (
C )
, J21 (
D )
S 1
+BM
+BS BZIG1
GND2 FL+FL–FR+ FR–RL+ RL–
(
RHD )
( LHD )
Buzzer
6
GND1
W–B
W–B
W–B
ABS Speed Sensor Front LH
ABS Speed Sensor Front RHABS Speed Sensor Rear LH
Junction
Connector
Skid Control ECU with Actuator
E 1
VSC Warning BuzzerV 7
EB
W–B
AVENSIS (EWD526E)
339
2
1
38 39
IE2
10 IE211
IM1
1IM1 10 IE2
2
DB
3
DC
2
1
31
IE1
14
6 9CJ
10
CA
6
IP IL
IE8
6
IE2
13 IE8
13
IE2
3 IE8
7
IE2
15 IE8
14
IE2
14 IE8
5
IE1
13
25
31243017
1819 8732
42
321
27 11 12
15A
STOP
From Power Source System
(
See Page 120 )
DA
22
1 2 IE3
6
DA
2
DL
2
37
G–W
G–W
R–W
( LHD )
R–W
( LHD )
R–W
( RHD )
R–W
( RHD )
G–W
( RHD )
G–W
( RHD )
G
L
Y
B
Y–B G
L
W (
∗ 3 )
B
Y–B
G–W
G–W
G–W
B–W
B–W
B–W PP
V
G–Y
V
G–Y
P
V
W–B
W–B
W–B
Y–GGR
Y–R
A3 3 O 1
S13
E 9
P 4
S 1
TRC+ TRC– ENG+ ENG– NEO
STP
RR+ RR– CSW VCM PMC E2 PKB
( LHD )
T 9
(
RHD )
(
LHD )
(
LHD )
( RHD )
(LHD )
( RHD )
(
LHD )
(
LHD )
∗
1 : 1AZ–FSE
∗ 2 : 1CD–FTV
∗ 3 : RHD 1AZ–FSE
∗ 4 : Except RHD 1AZ–FSE
IR1
1
IR1
2
IE3
11
TRC+ TRC– ENG+ ENG– NEO
ABS Speed Sensor Rear RH Engine and ECT ECU (
A/T )
Engine ECU (
M/T )
Oil Pressure Sensor
Parking Brake SW
Skid Control ECU with ActuatorStop Light SW
TRC Off SW
Y (
∗ 4 )
W–B
( RHD )
A A
J1 6Junction
Connector
340
AVENSIS (EWD526E)
VSC
S 1
IK
A A
DA BAA
IE8
1I E8
2I E8
9 IE8
10 IE8
3
BB
( Shielded )
(
Shielded )
A
BA A
AD
BEBDBB
B
( LHD )
W
( LHD ) W–G
( LHD )
W–L
( LHD )
W–G
( LHD )
W–L
( LHD )B
( LHD )
W
( LHD )
B
( LHD )
W
( LHD )
W–G
( LHD )
W–L
( LHD )
W–G
( LHD )
W–L
( LHD )
W
( LHD )
B
( LHD )
13 71 B
C
B
C
C
B
24 56
Y 1
S12
J 6 (
A )
, J 7 (
B )
J1 5
29 13 1630
SS2
SS1 YGND YIGAJ1 8
(
Shielded )(
Shielded)
( Shielded )
Junction Connector
Junction
Connector Junction Connector Skid Control ECU with Actuator
Steering Sensor Yaw Rate Sensor
GND UBAT
GND 12V
CAN
LOW
CAN
HIGH
CANH
CANL
W–B
( LHD )
AVENSIS (EWD526E) 341
(
Shielded )
(
Shielded )
YIGA
YGND
SS1
SS2
30
16
13
29
J1 9
S12 Y 1
6
5
4
2
7
1
(
RHD )
W
(
RHD )
B (
RHD )
W–G
(RHD )
W–L
(
RHD )
W–G
(
RHD )
W
(
RHD )
B
(RHD )
W
(
RHD )
B
13
(
RHD )
W–L
(
RHD )
W–G
(
RHD )
W–L
(
RHD )
W–G
( RHD )
W
(
RHD )
B (
Shielded )(
Shielded)
IK
A IO2
13 IO2 12 IO211IO1
11 IO112
BB A
BA B
W–B
( RHD )FF C B
F C B FC B
BA
A
CA C
W–G
( RHD )
J2 2(
A )
, J23 (
B )
J2 2
(
A )
, J23 (
B )
W–L
( RHD )
S 1
Junction Connector
Junction
Connector
Junction
Connector
Skid Control ECU with Actuator
Steering Sensor Yaw Rate SensorCANL CANH
CAN
LOWCAN
HIGH12V
GND
UBAT
GND
AB
AB
Junction
Connector
J 8
(
A )
DB
17
DL
15
W–L
( LHD ) W–L
( LHD )
W–L
( RHD )
W–L
( RHD )
DD
CB
TC
13
17
TC
W–L
Junction
ConnectorJ2 0 (
C )
, J21 (
D )AD
AD Junction
ConnectorJ 8
(
A )
W
( LHD )(
LHD)
W
W
( RHD )
W
( RHD )
CD
DB
TS
12
28
TS
W
Junction
ConnectorJ2 0 (
C )
, J21 (
D )CG
AG
DB
9
DL
1
W–G W–G
SIL
7
26
D/G
W–G
CG AG
(
LHD )
( RHD )
( LHD )
( RHD )
IE2
12 DLC3
D 5
Junction
ConnectorJ 8
(
A )
, J26 (
C )
Junction
ConnectorJ1 5
AW–B
( RHD ) W–B
( RHD )
342
AVENSIS (EWD526E)
VSC
7. 5A
DOME
From Power Source System
(
See Page 120 )
6
BH
CF
CF
Speedometer
IE1
16 B
19
B
20 B 21
10A
GAUGE1
DB
7
C10 (
A )
, C11 (
B )
S 1W–R
AF (
LHD )
J1 0(
A )
, J11 (
B )
, J26 (
C )
W–R
( RHD )
W–R
( LHD )
R–W
L–W
L–W
CA
7
CD
6
20 36 2 4 34 35 EBDW WA WT IND VSCW SP1
P
R–Y
LG–B
LG
W–R
L–W
W–R LG
LG–B R–Y P
R–W
CPU
Combination Meter
Junction Connector
Skid Control ECU with Actuator
5B
IP
6CA 6CK
W–B
W–B
(
RHD )
1
2
W–B
( RHD ) W–B
( RHD )
AVENSIS (EWD526E) 343
IE1
18
IE1
17
IE1
7
IE1
8
IE1
6 B
16 B 15 B17 A
9B 4B2
B
22 A
17
IE1
19
2 1
EC 1
10A
IGN
From Power Source System
(
See Page 120 )
DA
18 CA
(
RHD )
AC
(
LHD )
AC (
LHD )
CA (
RHD )
VSC
Slip
TRC OFF
ABS
Brake
AA
C
C
C
W–B
( LHD )
W–B
( RHD )
W–B
( RHD )
W–B
( LHD )
J 8(
A )
, J26 (
C )
J 2
V 2 B 3
J1 6 J1 7
C10(
A )
, C11 (
B )
B–W
W–R
LG
LG–B R–Y
P
R–W
R–W
R–W
W–B W–R
LG
LG–B R–Y
P B–W
R–W
( ∗ 2 )
R–W ( ∗ 2 )
(
∗ 1 )
( ∗ 2 )
W–R
LG
LG–B R–Y P ∗
1 : 1AZ–FSE
∗ 2 : 1CD–FTV
Brake Fluid Level
Warning SW
Combination Meter
Junction
Connector Junction
Connector
Junction
Connector Junction
Connector
W–B
( RHD ) A
A
W–B
( LHD ) W–B
( LHD )
W–B
( RHD )
IL : ∗
2
IO : ∗ 1
Vacuum SW
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