TOYOTA AVENSIS 1999 Supplement

F01876
Bushing
Front
Housing Vane Pump
Shaft
SR0WE–01
Z06061
Thickness
Height
Length
R10282
Feeler Gauge
F01319
Inscribed Mark
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–11
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.01 – 0.03 mm (0.0004 – 0.0012 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.1 mm (0.319 in.)
Minimum thickness: 1.797 mm (0.0708 in.)
Minimum length: 14.988 mm (0.5901 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with the one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None

F03747
F04785
Compressed Air
F01318
Inscribed Mark
SR–12– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
HINT:
There are 5 vane plate lengths with the following rotor and cam
ring marks:
Rotor and cam
ring markVane plate part
numberVane plate length
mm (in.)
None44345–1201014.996 – 14.998
(0.59039 – 0.59047)
144345–1202014.994 – 14.996
(0.59032 – 0.59039)
244345–1203014.992 – 14.994
(0.59024 – 0.59032)
344345–1204014.990 – 14.992
(0.59016 – 0.59024)
444345–1205014.988 – 14.990
(0.59008 – 0.59016)
3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it
falls smoothly into the valve hole by its own weight.
(b) Check the flow control valve for leakage. Close one of the
holes and apply compressed air 392 – 490 kPa (4 – 5
kgf/cm
2, 57 – 71 psi) into the opposite side hole, and con-
firm that air does not come out from the end hole.
If necessary, replace the valve with the one having the same let-
ter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

R08702
F01345
Vinyl Tape
F01317
Press
Oil Seal SST
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–13
4. INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 36.0 mm (1.417 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver with vinyl tape wound around its tip,
remove the oil seal.
NOTICE:
Be careful not to damage the front housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST and a press, press in the oil seal.
SST 09950–60010 (09951–00310),
09950–70010 (09951–07100)
NOTICE:
Make sure to install the oil seal facing the correct direction.

SR0WF–01
Z13635
Inscribed Mark
F03721
Longer
Straight Pin
Hole
F01314
Inscribed Mark
SR–14– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID (See page SR–6)
2. INSTALL LONGER STRAIGHT PIN
Using a plastic hammer, tap in a new longer straight pin to the
front housing.
NOTICE:
Be careful not to damage the pin.
3. INSTALL SHORTER STRAIGHT PIN
Install a new short straight pin to the side front plate.
NOTICE:
Be careful not to damage the pin.
4. INSTALL SIDE FRONT PLATE AND VANE PUMP RO-
TOR
(a) Coat 2 new O–rings with power steering fluid and install
them to the side front plate.
(b) Install the plate to the pump shaft.
NOTICE:
Make sure to install the plate facing the correct direction.
(c) Install the vane pump rotor to the pump shaft with the in-
scribed mark facing outward.
(d) Install a new snap ring to the vane pump shaft.
5. INSTALL VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
Align the hole of the side front plate and longer straight pin, and
tap in the shaft with a plastic hammer.
NOTICE:
Be careful not to damage the oil seal and O–rings.
6. INSTALL CAM RING
Align the holes of the cam ring and 2 straight pins and install the
ring with the inscribed mark facing outward.

F01315
Round End
F01316
F03722
Press
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–15
7. INSTALL VANE PLATES
Install the 10 plates with the round end facing outward.
8. INSTALL SIDE REAR PLATE
(a) Coat a new O–ring with power steering fluid and install it
to the side rear plate.
(b) Align the holes of the plate and 2 straight pins, and install
the plate.
9. INSTALL WAVE WASHER
Install the washer so that its protrusions fit into the slots in the
side rear plate.
10. INSTALL REAR HOUSING
(a) Coat a new O–ring with power steering fluid and install it
to the rear housing.
(b) Install the housing and use a press to push down on the
wave washer hard enough to compress it.
NOTICE:

Do not apply too much pressure.

Be careful not to damage the O–ring.
(c) Install a new snap ring.
11. INSTALL SPRING AND FLOW CONTROL VALVE
Install the valve facing the correct direction
(See page SR–6).
12. INSTALL PRESSURE PORT UNION
(a) Coat a new O–ring with power steering fluid and install it
to the pressure pore union.
(b) Install the union.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
13. INSTALL SUCTION PORT UNION
(a) Coat a new O–ring with power steering fluid and install it
to the suction port union.
(b) Install the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
14. MEASURE PS VANE PUMP ROTATING TORQUE
(See page SR–9)

SR0WG–01
F04155
SST
F08958
SR–16– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
INSTALLATION
1. INSTALL PULLEY COVER
Install the pulley cover to the PS vane pump with the bolt.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
2. INSTALL PS VANE PUMP ASSEMBLY
Install the PS vane pump to the pulley bracket and engine with
the 3 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
3. CONNECT PRESSURE FEED TUBE
Place a new gasket to the pressure feed tube and connect them
with the union bolt.
Torque: 52 N·m (525 kgf·cm, 38 ft·lbf)
4. CONNECT RETURN HOSE
Connect the return hose with the clip.
5. INSTALL VANE PUMP PULLEY
(a) Install the woodruff key to the vane pump shaft.
(b) Install the vane pump pulley.
(c) Using SST to stop the pulley rotating, torque the nut.
SST 09960–10010 (09962–01000, 09963–01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
6. INSTALL DRIVE BELT
(a) Install the drive belt to the pulley.
(b) Adjust drive belt tension with the belt tension adjusting
bolt (See page SR–1).
(c) Torque the idler pulley set nut.
Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)
7. BLEED POWER STEERING SYSTEM
(See Pub. No. RM599E on page SR–5)

SUPPLEMENTAL RESTRAINT SYSTEM
SRS AIRBAG RS–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE AIRBAG ASSEMBLY RS–9. . . . . . . . . . . . . . . .
CURTAIN SHIELD AIRBAG ASSEMBLY RS–20. . . .
SIDE AND CURTAIN SHIELD
AIRBAG SENSOR ASSEMBLY RS–34. . . . . . . . . .
WIRE HARNESS AND CONNECTOR RS–39. . . . . .
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. RM599E)
NOTE: The above pages contain only the points which differ
from the above listed manual.

RS0IJ–01
– SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS–1
SRS AIRBAG
PRECAUTION
NOTICE:

The AVENSIS / CORONA is equipped with SRS, which comprises a driver airbag, front passen-
ger airbag, side airbag and curtain shield airbag. Failure to carry out service operations in the
correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly lead-
ing to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that
the SRS may fail to operate when required. Before performing servicing (including removal or
installation of parts, inspection or replacement), be sure to read the following items carefully,
then follow the correct procedures described in the repair manual.

Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the side airbag assembly,
curtain shileld airbag assembly and side and curtain shield airbag sensor assembly should be
inspected (See page RS–11, RS–25 and RS–36).

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the side airbag assembly, curtain shield airbag assembly or side
and curtain shield airbag sensor assembly in order to reuse it.

If the side airbag assembly, curtain shield airbag assembly or side and curtain shield airbag
sensor assembly has been dropped, or if there are cracks, dents or other defects in the case,
bracket or connector, replace it with new one.

Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s
electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.

After working on the SRS is completed, perform the SRS warning light check (See Pub No.
RM599E on page DI–152).

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:

Work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and
the negative (–) terminal cable is disconnected from the battery.
(The SRS is equipped with a back–up power source so that if work is started within 90 seconds
from disconnecting the negative (–) terminal cable of the battery, the SRS may be deployed.)

When the negative (–) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back– up power supply from outside the vehicle.

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

Do not expose the side airbag assembly, curtain shield airbag assembly or side and curtain
shield airbag sensor assembly directly to hot air or flames.

RS0IK–01
H03384
H11628
H03386
H03387
H03388
RS–2
– SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
OPERATION
1. SIDE AIRBAG ASSEMBLY
The inflater and bag of the SRS side airbag are stored in the
side airbag assembly and cannot be disassembled. The inflater
contains a squib, igniter charge and gas generant, etc., and in-
flates the bag when instructed by the side airbag sensor assem-
bly.
2. CURTAIN SHIELD AIRBAG ASSEMBLY
The inflater and bag of the SRS curtain shield airbag are stored
in the curtain shield airbag assembly and cannot be disas-
sembled. The inflater contains a squib, igniter charge and gas
generant, etc., and inflates the bag when instructed by the side
airbag sensor assembly.
3. SRS WARNING LIGHT
The SRS warning light is located on the combination meter. It
goes on to alert the driver of trouble in the system when a mal-
function is detected in the airbag sensor assembly. In normal
operation conditions when the ignition switch is turned to the
ACC or ON position, the light goes on for about 6 seconds and
then goes off.
4. AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the
lower center finish panel. The airbag sensor assembly consists
of an airbag sensor, safing sensor, diagnosis circuit ignition
control and drive circuit, etc. It receives signals from the airbag
sensor, front airbag sensor, side airbag sensor and judges
whether the SRS must be activated or not.
5. SIDE AND CURTAIN SHIELD AIRBAG SENSOR AS-
SEMBLY
The side and curtain shield airbag sensor assembly is mounted
in the LH and RH center pillars. The side airbag sensor assem-
bly consists of a side airbag, sensor, safing sensor and diagno-
sis circuit, etc. It sends signals to the airbag sensor assembly
to judges whether the SRS side airbag must be activated or not.