fluid TOYOTA AVALON 2001 Service Manual PDF

SR0EE-03
R11741
Normal Abnormal SR-4
- STEERINGPOWER STEERING FLUID
1467 Author
: Date
:
2001 AVALON (RM808U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR-5)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the steering wheel slowly from
lock to lock several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the steering wheel to left or
right full lock position and keep it there for 2-3 seconds,
then turn the steering wheel to the opposite full lock posi-
tion and keep it there for 2-3 seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR-5)

R11740
HOT
COLD
SR0EF-04
R11741
Normal Abnormal
R11786Engine Idling
Engine Stopped 5 mm (0.20 in.)
or less
- STEERINGPOWER STEERING FLUID
SR-5
1468 Author
: Date
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2001 AVALON (RM808U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir. If the fluid is cold, check that it is within the COLD
LEVEL range.
(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 power steering sys-
tem (See page SR-4).
(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 (See page
SR-4).
(i) Check the fluid level.

R14662
Attachment
IN
OUT Pressure Feed Tube SST
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST Closed SR-6
- STEERINGPOWER STEERING FLUID
1469 Author
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2001 AVALON (RM808U)
2. CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube (See page SR-27).
(b) Connect SST to pressure feed tubes, as shown in the il-
lustration below.
SST 09640- 10010 (09641- 01010, 09641- 01030,
09641-01060)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system (See page SR-4).
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 °C (176 °F)
(f) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Minimum fluid pressure:
7,845 kPa (80 kgf/cm
2, 1,138 psi)
NOTICE:

Do not keep the valve closed for more than 10 se-
conds.

Do not let the fluid temperature become too high.

Z15499
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open
Z15500
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open Lock Position
- STEERINGPOWER STEERING FLUID
SR-7
1470 Author
: Date
:
2001 AVALON (RM808U)
(g) With the engine idling, open the valve fully.
(h) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Difference fluid pressure:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
(i) With the engine idling and valve fully opened, turn the
steering wheel to full lock.
Minimum fluid pressure:
7,845 kPa (80 kgf/cm
2, 1,138 psi)
NOTICE:

Do not maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(j) Disconnect the SST.
SST 09640- 10010 (09641- 01010, 09641- 01030,
09641-01060)
(k) Connect the pressure feed tube (See page SR-35).
(l) Bleed the power steering system (See page SR-4).

SR0ET-05
F09931
Stabilizer Bar
Clamp PlateNo. 1 Fuel Tube Protector
Intermediate Shaft
Sub-assembly
Return Tube
Pressure Feed Tube
PS Gear Assembly
* For use with SSTCotter Pin  Non-reusable part
19 (190, 14)
19 (190, 14)
10 (100, 7)
35 (360, 26)
181 (1,850, 134)
181 (1,850, 134)
49 (500, 36)
49 (500, 36)N´m (kgf´cm, ft´lbf) : Specified torque
25 (250, 18)
*28 (290, 21)
Cotter Pin25 (250, 18)
*28 (290, 21)
O-Ring 
Power steering fluid

- STEERINGPOWER STEERING GEAR
SR-37
1500 Author
: Date
:
2001 AVALON (RM808U)
POWER STEERING GEAR
COMPONENTS

Z19562
 O-Ring
* For use with SST  Non-reusable partRack Housing
No. 2 Grommet
Rack HousingRack Boot
Clip
Tie Rod End
Lock Nut
Rack End
Steering Rack Rack Housing
No. 2 Bracket Clamp
 Claw Washer
 Teflon Ring
 Oil Seal
 Wire
 Oil Seal
Molybdenum disulfide lithium base grease
Power steering fluidCylinder End Stopper
Bushing  Claw Washer Rack End
83 (850, 61)
*60 (610, 44)
 Clamp Rack Boot Clip
Lock Nut Tie Rod End
74 (750, 54)
74 (750, 54)
N´m (kgf´cm, ft´lbf) : Specified torque
 O-Ring
83 (850, 61)
*60 (610, 44)
SR-38
- STEERINGPOWER STEERING GEAR
1501 Author
: Date
:
2001 AVALON (RM808U)

F09751
 Non-reusable part Oil Seal  O-Ring
Molybdenum disulfide lithium base grease
Power steering fluid
Precoated part O-Ring Turn Pressure Tube
Dust Seal

Control Valve AssemblyControl Valve
Housing Turn Pressure Tube

 Oil Seal
 Bearing
 Teflon Ring
 Bearing
 Gasket
Rack Guide Spring
Rack Guide Sub-assembly
Rack Housing
 Bearing
Rack Guide
Spring Cap Lock Nut

Rack Guide
Spring Cap
 Self-locking Nut

Rack Housing Cap
13 (130, 9)
*12 (120, 9)
18 (180, 13)
18 (180, 13)
69 (700, 51)
*50 (510, 37)
25 (250, 18)
59 (600, 43)
N´m (kgf´cm, ft´lbf): Specified torque
* For use with SST
- STEERINGPOWER STEERING GEAR
SR-39
1502 Author
: Date
:
2001 AVALON (RM808U)

SR0EY-06
F13589
SST
Fulcrum Length
SR-56
- STEERINGPOWER STEERING GEAR
1519 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
(a) Install the PS gear assembly from the LH of the vehicle.
NOTICE:
Do not damage the turn pressure tubes.
(b) Install the 2 gear assembly set bolts and nuts.
Torque: 181 N´m (1,850 kgf´cm, 134 ft´lbf)
HINT:
Lift up the stabilizer bar and install the bolts.
2. INSTALL NO. 1 FUEL TUBE PROTECTOR
Install the No. 1 fuel tube protector with 2 bolts and nut.
3. CONNECT STABILIZER BAR
Connect the stabilizer bar with the 4 bolts.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
4. CONNECT PRESSURE FEED AND RETURN TUBES
(a) Coat 2 new O-rings with power steering fluid and install
them to the pressure feed and return tubes.
(b) Using SST, connect the pressure feed and return tubes.
SST 09023-38400
Torque: 28 N´m (290 kgf´cm, 21 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.
5. CONNECT CLAMP PLATE
Connect the clamp plate with nut.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
6. CONNECT INTERMEDIATE SHAFT SUB-ASSEMBLY
(See page SR-22)
7. CONNECT RH AND LH TIE ROD ENDS
(See page SA-13)
8. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
9. CENTER SPIRAL CABLE (See page SR-22)
10. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and steering
column main shaft.
(b) Temporarily tighten the steering wheel set nut.
(c) Connect the connector.
11. BLEED POWER STEERING SYSTEM
(See page SR-4)

W03561
Press
SST
Oil Seal SST
SR0RW-03
W02101
SST
Rack Teeth End
R11574
Vinyl TapeBushing
- STEERINGPOWER STEERING GEAR
SR-49
1512 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID OR MOLYBDENUM DISULFIDE
LITHIUM BASE GREASE (See page SR-37)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950- 60010 (09951- 00240, 09951- 00430,
09952-06010), 09950-70010 (09951-07360)
NOTICE:

Make sure that the oil seal is installed facing in the
correct direction.

Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK
(a) Install SST to the steering rack.
SST 09631-33010
HINT:
If necessary, scrape the burrs off the steering rack teeth end
and burnish.
(b) Coat the SST with power steering fluid.
(c) Install the steering rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal lip.
(d) Remove SST.
SST 09631-33010
4. INSTALL BUSHING
(a) Coat a new O-ring with power steering fluid and install it
to the bushing.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the bushing.
NOTICE:

Make sure that the bushing is installed facing in the
correct direction.

Be careful not to damage the oil seal lip.

R11656
Cylinder
End StopperWire SST
R00662
SST
R11657
R11658
R11575
Vinyl Tape SR-50
- STEERINGPOWER STEERING GEAR
1513 Author
: Date
:
2001 AVALON (RM808U)
5. INSTALL CYLINDER END STOPPER
(a) Align the installation hole for the wire of the cylinder end
stopper with the slot of the rack housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using SST, turn the cylinder end stopper clockwise 450
± 50°.
SST 09631-10021
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL RACK HOUSING NO. 2 BRACKET AND
RACK HOSING NO. 2 GROMMET
(a) Install the rack housing No. 2 grommet to the rack housing
No. 2 bracket.
HINT:
Align the projection of the rack housing No. 2 grommet with the
hole of the rack housing No. 2 bracket.
(b) Align the matchmarks on the rack housing No. 2 bracket
and rack housing.
(c) Place the rack housing No. 2 bracket in a vise and install
the vise to fasten the clamp.
8. INSTALL CONTROL VALVE ASSEMBLY
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the control valve shaft.
(b) Coat the teflon rings with power steering fluid.
(c) Install the control valve assembly into the control valve
housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.