TOYOTA AVENSIS 2005 Service Repair Manual

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.

Z15500
Oil
ReservoirPS Vane
Pump
PS Gear
SST(s)
Open
Lock Position
F08858
±
POWER STEERING POWER STEERING SYSTEM
51±7
AVENSIS REPAIR MANUAL (RM1018E)
(k) With the engine idling and valve fully opened, turn the
steering wheel to full lock position.
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 maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(l) Remove SST(s).
(m) AZ Series:
Connect the pressure feed tube assy to the vane pump
assy (See page 51±9).
(n) 1CD±FTV:
Connect the pressure feed tube assy to the vane pump
assy (See page 51±19).
(o) Bleed the power steering system.
5. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b)Remove the steering wheel pad (See page 60±17).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions. Steering effort (Reference):
5.5 N´m (56 kgf´cm, 49 in.´lbf)
HINT:
Take the tire type, pressure and contact surface into consider-
ation before making your diagnosis.
(e) Torque the steering wheel set nut. Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
(f)Install the steering wheel pad (See page 60±17).

550YV±01
I35275
N
m (kgf
cm, ft
lbf) : Specified torque
9.8 (100, 87 in.
lbf)
9.8 (100, 87 in.
lbf)
Defroster Nozzle Assy
Heater To Register Duct No.1
Blower Assy
Air Conditioning Radiator Assy
Instrument Panel Brace Sub±assy No.1
Air Duct Rear No.3Air Duct Rear No.4
9.8 (100, 87 in.
lbf)
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±53
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING RADIATOR ASSY
COMPONENTS

I35276
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

Compressor oil ND±OIL 8 or equivalentCooler Thermistor No.1
Auto A/C:
Airmix No.2 Damper
Servo Sub±assy
Heater Piping CoverMode Damper Servo
Sub±assy
Airmix Damper Servo Sub±assy
w/o Hot gas heater:
Cooler Expansion Valve
Cooler Evaporator
Sub±assy No.1
Cooler Unit Drain Hose No.1
Air Conditioning
Tube Assy
Heater Radiator Unit Sub±assyAir Duct No.1Air Duct No.2
w/o Hot gas heater:
Air Conditioning
Tube Assy
w/ Hot gas heater:
O±ring


O±ring


3.5 (35, 30 in.
lbf)
Cooler Air Hose
RHD Auto A/C:
Air Conditioning
Wire No.1
55±54
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)

550YU±01
I37428
I352826 Claws
I352864 Claws
55±50
±
HEATER & AIR CONDITIONER AIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±48
1.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
2.REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
4.REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (See page 67±5)
5.REMOVE RADIO BRACKET NO.1 (See page 67±5)
6.REMOVE RADIO BRACKET NO.2 (See page 67±5) 7. REMOVE AIR CONDITIONING CONTROL ASSY
(a) Remove the air conditioning control assy as shown in theillustration.
8. REMOVE AIR CONDITIONING PANEL SUB±ASSY
(a) Remove the 4 screws.
(b) Manual A/C: Release the 6 claw fittings and disconnect the air condi-
tioning panel sub±assy.
(c) Auto A/C: Release the 4 claw fittings and disconnect the air condi-
tioning panel sub±assy.

I35287
Auto A/C:
I35283
Manual A/C:
I35284
I35285
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
55±51
AVENSIS REPAIR MANUAL (RM1018E)
(d) Disconnect the cooler wire No.1 as shown in the illustra-
tion.
9. REMOVE HEATER CONTROL KNOB NO.3 (MANUAL AIR CONDITIONING)
10. REMOVE CONTROL KNOB SUB±ASSY (AUTO AIR CONDITIONING)
11. REMOVE HEATER CONTROL KNOB (MANUAL AIR CONDITIONING)
12. REMOVE HEATER CONTROL KNOB NO.2 (MANUAL AIR CONDITIONING)
13. REMOVE HEATER CONTROL HOUSING (MANUAL
AIR CONDITIONING)
(a) Release the 4 claw fittings and remove the 4 screws and
the heater control housing.
14. REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)
15. REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)
16. REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)
17. REMOVE AIR CONDITIONING CONTROL BULB
(MANUAL AIR CONDITIONING)
(a) Remove the 4 air conditioning control bulbs.

I35833
Manual A/C:
Auto A/C:

I35834
Manual A/C:
Auto A/C: 55±52
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE HEATER CONTROL HOUSING SUB±ASSY (MANUAL AIR CONDITIONING)
19. REMOVE HEATER CONTROL HOUSING
(a) Remove the 4 screws and the heater control housing.
20. REMOVE COOLER WIRE NO.1
(a) Remove the cooler wire No.1 as shown in the illustration.

550YT±01
I35273
Manual A/C:
Heater Control HousingAir Conditioning Control Assy
Air Conditioning Control Bulb
Heater Control Housing Sub±assy
Heater Control Lens Assy
Heater Control Housing
Heater Control Knob No.2
Heater Control Knob No.3Heater Control Knob
Cooler Wire No.1
Air Conditioning Panel Sub±assy 55±48
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING CONTROL ASSY
COMPONENTS

I35274
Auto A/C:
Air Conditioning Control Assy
Cooler Wire No.1 Heater Control Housing
Control Knob Sub±assy
Air Conditioning Panel Sub±assy
± HEATER & AIR CONDITIONERAIR CONDITIONING CONTROL ASSY
55±49
AVENSIS REPAIR MANUAL (RM1018E)