TOYOTA AVENSIS 2002 Repair Manual

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).

510DK±02
D29958
LHD:
Pressure Feed
Tube Assy8.0 (82, 71 in.
lbf)
Steering Gear Outlet
Return Tube
44.1 (450, 33)
*41 (414, 30)
Steering Intermediate Shaft Assy No.2
35 (360, 26)
Steering Intermediate Shaft
Column Hole Cover
Silencer Sheet
Clip
Steering Gear Outlet Return Tube
Pressure Feed Tube Assy Steering Column Hole
Cover Sub±assy No.1

Cotter Pin
Rack & Pinion Power
Steering Gear Assy
Stopper Rear
80 (816, 59)
80 (816, 59)
133 (1,356, 98)
Front Stabilizer
Link Assy RH
Stopper
Front
133 (1,356, 98)
89 (908, 66)
74 (755, 55)
Front Stabilizer Link Assy LH
Stopper Rear
Crossmember
Bracket LH
80 (816, 59)
133 (1,356, 98)
80 (816, 59)
N
m (kgf
cm, ft
lbf): Specified torque
Non±reusable part
* For use with SST(s)
52 (530, 38)
133 (1,356, 98)
52 (530, 38)
Center Member
74 (755, 55)49 (500, 36)
Front Suspension
Crossmember Sub±assy
Stopper Front
49 (500, 36)
35 (360, 26)
89 (908, 66)
Engine Under Cover LH Engine Under
Cover RH
45 (459, 33)
49 (500, 36)49 (500, 36)
49 (500, 36)
44.1 (450, 33)
*41 (414, 30)
44.1 (450, 33)
*41 (414, 30)
51±34
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
RACK & PINION POWER STEERING GEAR ASSY
COMPONENTS

D30602
Tie Rod End Sub±assy RH
Lock NutSteering Rack Boot Clip
Steering Rack Boot No.1
Steering Rack Boot
No.1 Clamp

Lock Nut
Steering Rack
Boot No.2 Clamp

Steering Rack Boot
No.2
Steering Rack Boot Clip
Tie Rod End Sub±assy LH

Non±reusable part
Silicon greaseN
m (kgf
cm, ft
lbf) : Specified torque
74 (750, 54)
74 (750, 54)
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51±35
AVENSIS REPAIR MANUAL (RM1018E)

510DL±02
D30509



D30705
LHD:
A
B
RHD:
Matchmarks
Matchmarks
A
B
51±36
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
NOTICE:
When installing, coat the parts indicated by the arrows with power steering fluid or molybdenum dis-
ulfide lithium base grease (See page 51±34).
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9) 3. SEPARATE STEERING INTERMEDIATE SHAFT ASSYNO.2
(a) To prevent form rotating the steering wheel, fix the wheel with the seat belt.
HINT:
The operation is useful to prevent the damage of the spiral
cable.
(b) Place matchmarks on the intermediate shaft assy No.2 and the intermediate shaft.
(c) Loosen the bolt A and remove the bolt B, then separate the intermediate shaft assy No.2.
4. SEPARATE STEERING COLUMN HOLE COVER SUB±ASSY NO.1
5. REMOVE FRONT WHEELS
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE ENGINE UNDER COVER RH
8.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
9. SEPARATE TIE ROD END SUB±ASSY RH
SST 09628±62011
HINT:
Perform the same procedure on the other side.

D29965
RHD:
LHD:
SST(s)
SST(s)
D29966
RHD:
LHD:
SST(s)
SST(s)
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±37
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
11. DISCONNECT STEERING GEAR OUTLET RETURNTUBE
(a) Using SST(s), disconnect the outlet return tube. SST 09023±12700
(b) LHD: Remove the bolt and separate the tube clamp from the
power steering gear assy.
12. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Using SST(s), disconnect the pressure feed tube assy. SST 09023±12700
13.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
14. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.

\b
D30389
AZ Series:1CD±FTV:
No.1 Engine Hanger
No.2 Engine Hanger
No.1 Engine Hanger
No.2 Engine Hanger
No.1 Engine
Hanger UPR
D29969
C94595
51±38
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
15.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
16. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
17. REMOVE HOOD SUB±ASSY
18. REMOVE CYLINDER HEAD COVER SUB±ASSY 19. SUSPEND ENGINE ASSEMBLY
(a) Install the 2 or 3 engine hangers with the bolts in the cor-rect direction.
Parts No. :
AZ Series:1CD±FTV:
No.1 Engine Hanger12281±2801012281±27050
No.1 Engine Hanger UPR±Yellow: 12284±27020
Black: 12284±27030
No.2 Engine Hanger12282±28010Yellow: 12282±27060Black: 12282±27070
Bolt91512±6102091642±81025
Torque:
AZ Series:
38 N
m (390 kgf
cm, 28 ft
lbf)
1CD±FTV:
37 N
m (375 kgf
cm, 27 ft
lbf)
(b) Attach the engine chain hoist to the engine hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other parts.
20. REMOVE FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Remove the 4 bolts and separate the center member.
(b) Remove the bolt and the 3 nuts, separate the engine mounting insulator RR from the crossmember sub±assy.
(c) Using a transmission jack, support the crossmember
sub±assy.

C94596
LH:
C94597
RH:
C94598
D30593
Matchmarks
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51±39
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove the 4 bolts and the crossmember bracket LH.
(e) Remove the stopper rear from the crossmember bracket
LH.
(f) Remove the 4 bolts and the crossmember bracket RH.
(g) Remove the stopper rear from the crossmember bracket
RH.
(h) Remove the 2 nuts and the crossmember sub±assy w/
power steering gear assy.
(i) Remove the 2 stopper front from the crossmember sub±
assy.
21. REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1
22. REMOVE STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the intermediate shaft and the pin-
ion shaft.
(b) Remove the bolt and the intermediate shaft.

D30594
F40050
Matchmarks
ZK8184
F40083
51±40
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
23. REMOVE RACK & PINION POWER STEERING GEAR
ASSY
(a) Remove the 4 bolts, the nuts and the power steering gear
assy from the crossmember sub±assy.
NOTICE:
Because the nut has its own stopper, do not turn the nut
and torque the bolt with the nut fixed.
24. REMOVE TIE ROD END SUB±ASSY LH
(a) Place matchmarks on the tie rod end sub±assy and the
rack end.
(b) Loosen the lock nut, and remove the tie rod end sub±assy
and the lock nut.
25. REMOVE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
26. INSPECT TIE ROD END SUB±ASSY LH
(a) Secure the tie rod end sub±assy in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torx wrench, turn the nut continuously at a rate of
2 to 4 seconds per turn and take the torque reading on the
5th turn.
Turning torque:
0.49 to 3.43 N
m (5.0 to 35 kgf
cm, 4.34 to 30.38 in. lbf)
27. INSPECT TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
28. REMOVE STEERING RACK BOOT NO.2 CLAMP
(a) Using a screwdriver, remove the rack boot No.2 clamp.
NOTICE:
Be careful not to damage the boot.

C57755
F400843 mm (0.12 in.) or less
SST(s)
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51±41
AVENSIS REPAIR MANUAL (RM1018E)
29. REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT:
Perform the same procedure on the other side.
30. REMOVE STEERING RACK BOOT CLIP
HINT:
Perform the same procedure on the rack boot clamps.
31. REMOVE STEERING RACK BOOT NO.2
32. REMOVE STEERING RACK BOOT NO.1
33. INSTALL STEERING RACK BOOT NO.2
(a) Apply silicon grease to the inside small caliber of rack
boot No.2.
(b) Install the rack boot No.2 to the groove on the rack hous-
ing.
NOTICE:
Be careful not to damage or twist the boot.
34. INSTALL STEERING RACK BOOT NO.1
HINT:
Perform the same procedure on the other side.
35. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Install a new rack boot No.2 clamp.
(b) Using SST(s), stake the rack boot No.2 clamp as shown
in the illustration.
SST 09521±24010
36. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09521±24010
HINT:
Perform the same procedure on the other side.
37. INSTALL STEERING RACK BOOT CLIP
SST 09521±24010
HINT:
Perform the same procedure on the rack boot clamps.

F41467
Matchmarks
D30594
D30593
Matchmarks
51±42
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
38. INSTALL TIE ROD END SUB±ASSY LH
(a) Screw the lock nut and the tie rod end sub±assy to the rack end until the matchmarks are aligned.
Torque: 74 N
m (750 kgf
cm, 54 ft
lbf)
HINT:
After adjusting toe±in, torque the lock nut
(See page 26±6).
39. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side. 40. INSTALL RACK & PINION POWER STEERING GEARASSY
(a) Install the power steering gear assy with the 4 bolts and the nuts.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
NOTICE:

The 4 bushings must be securely installed to the pow-
er steering gear assy.

When tightening the bolts for power steering gear, the
bushings should not be bitten in.

Because the nut has its own stopper, do not turn the
nut and torque the bolt with the nut fixed.
41. INSTALL STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the intermediate shaft with the pinion shaft.
(b) Install the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
42. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1