torque TOYOTA AVENSIS 1999 Supplement

BR11S–01
F08980
F08981
F08982
New O–Ring
F08970
F08969
– BRAKEVACUUM PUMP (1CD–FTV)
BR–7
REASSEMBLY
1. INSTALL COUPLING
(a) Place the coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
2. INSTALL ROTOR INTO CASING
Coat the rotor with engine oil, and install it to the rotor shaft.
3. INSTALL 5 BLADES
(a) Coat the 5 blades with engine oil.
(b) Install the 5 blades with the round end facing outward.
HINT:
Be sure that the blades and rotor surfaces are even.
4. INSTALL END COVER
(a) Coat 2 new O–rings with engine oil, and place them to the
casing.
(b) Place the vacuum pump on the vise, as shown in the il-
lustration.
NOTICE:
Do not tighten the vise.
(c) Place the end cover, and temporarily install the 3 bolts.
(d) Using a pin punch and hammer, drive in the 2 straight
pins.
(e) Using soft jaws on the vise, place the vacuum pump in the
vise.
NOTICE:
Do not tighten the vise too tightly.
(f) Tighten the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

F08984
New Gasket
F08985
New Gasket
New Gasket BR–8
– BRAKEVACUUM PUMP (1CD–FTV)
5. INSTALL CHECK VALVE
Install the check valve with a new gasket.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
6. INSTALL VACUUM HOSE UNION
Install the vacuum hose union and 2 new gaskets with the union
bolt.
Torque: 14 N·m (140 kgf·cm, 10 ft·lbf)
HINT:
Align and insert the union pin into the matching hole of the cas-
ing.

BR11T–01


F08964
New O–RingVacuum Hose
Oil Hose
– BRAKEVACUUM PUMP (1CD–FTV)
BR–9
INSTALLATION
1. INSTALL VACUUM PUMP
(a) Coat 2 new O–rings with engine oil, and install them to the
vacuum pump.
(b) Insert the vacuum pump, align the coupling with slit of the
camshaft.
(c) Install the 2 bolts.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
2. CONNECT 2 VACUUM HOSES AND OIL HOSE

SR0WB–01
F08960
 Gasket Union Bolt
Pressure Feed Tube
PS Vane Pump
Assembly Woodruff Key
Vane Pump Pulley
Drive Belt
Idler PulleyReturn Hose
N·m (kgf·cm, ft·lbf): Specified torque
 Non–reusable part
Pulley Cover
43 (440, 32)
39 (400, 29)
39 (400, 29)
38 (390, 28)
52 (525, 38)
SR–6– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
POWER STEERING VANE PUMP (2C–T, 2C–TE, 1CD–FTV)
COMPONENTS

F03716
N·m (kgf·cm, ft·lbf): Specified torque
 Non–reusable partPressure Port Union
 Shorter Straight Pin
 O–Ring  Snap Ring  O–Ring
 Longer Straight PinSide Front Plate
Flow Control Valve
Spring
 Oil Seal
Front HousingSuction Port UnionVane Pump
Shaft
Power steering fluid
69 (700, 51)
13 (130, 9)
 O–Ring
 O–Ring
 O–Ring  Snap Ring
Cam Ring
Rear Housing
Wave Washer  O–Ring
Side Rear Plate Vane Pump RotorVane Plate
x10
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–7

SR0WD–01
F03717
F03718
F03719
Vinyl Tape
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–9
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Temporarily install the vane pump pulley set nut.
(c) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE SUCTION PORT UNION
(a) Remove the bolt and suction port union.
(b) Remove the O–ring from the union.
3. REMOVE PRESSURE PORT UNION
(a) Remove the pressure port union.
(b) Remove the O–ring from the union.
4. REMOVE FLOW CONTROL VALVE AND SPRING
5. REMOVE REAR HOUSING, WAVE WASHER AND SIDE
REAR PLATE
(a) Using 2 screwdrivers, remove the snap ring.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the vane pump shaft.
(c) Using a plastic hammer, tap out the rear housing, wave
washer and side rear plate.
(d) Remove the O–ring from the rear housing.
(e) Remove the O–ring from the side rear plate.
6. REMOVE CAM RING AND 10 VANE PLATES
NOTICE:
Be careful not to drop the plate.
7. REMOVE VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
8. REMOVE VANE PUMP ROTOR AND SIDE FRONT
PLATE
(a) Using a screwdriver, remove the snap ring from the vane
pump shaft.
(b) Remove the vane pump rotor and side front plate.
(c) Remove the 2 O–rings from the side front plate.
9. REMOVE SHORTER STRAIGHT PIN
Using pliers, remove the shorter straight pin from the side front
plate.

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)

RS0IL–01
H11625
: Specified torque
 Non–reusable partHeadrest
Headrest Support
Lumber Support Adjusting Knob
Seatback Pad
Seatback CoverSeatback
Frame
25 (255, 18)
25 (255, 18)
Side Airbag
Assembly
Front Seat Cushion
Assembly
37 (375, 27)
37 (375, 27)
Front Seat Belt Lap Outer Anchor
42 (430, 31)
Front Seat Cushion Outer Shield
Reclining Adjuster Knob Front Seat Cushion
Inner ShieldHog Ring
N·m (kgf·cm, ft·lbf)Seat Track Cover
– SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
RS–9
SIDE AIRBAG ASSEMBLY
COMPONENTS

RS0IQ–01
H03410
H03411
H03408
– SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
RS–19
INSTALLATION
NOTICE:
Never use airbag parts from another vehicle. When replac-
ing parts, replace them with new parts.
1. INSTALL THESE PARTS TO SEATBACK FRAME
(a) Install the seatback pad.
(b) Install the hog rings and seatback cover.
(c) Hang the hook of the seatback cover.
2. INSTALL SEATBACK TO SEAT CUSHION ASSEMBLY
Using a torx wrench, install the 4 screws and seatback assem-
bly.
Torx wrench: T40 (Part No.09042–00020 or locally
manufactured tool)
Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)
3. INSTALL THESE PARTS TO FRONT SEAT ASSEMBLY
(a) Install the 2 headrest supports.
(b) Install the headrest.
(c) Install the lumber support adjusting knob.
(d) Install the front seat inner shield.
4. INSTALL FRONT SEAT
(a) Mount the seat to the vehicle.
(b) Connect the side airbag connector.
(c) Install the outer bolt and inner bolt on the front side after
sliding the seat to the rearmost position.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(d) Tighten the bolts on the rear side temporarily, tighten
them completely starting from the bolt on the inner side.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(e) Install the front seat belt lap outer anchor.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
(f) Install the front seat cushion outer shield and reclining ad-
juster knob.
(g) Install the 2 seat track covers.