TOYOTA AVENSIS 2003 Service Repair Manual

5100F±06
±
POWER STEERING POWER STEERING SYSTEM
51±1
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING SYSTEM
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Care must be taken to replace parts properly because they could affect the performance of the steering
system and result in a driving hazard.
2. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as \
the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence \
could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious acc\
ident. Before servicing (in-
cluding removal or installation of parts, inspection or replacement), be sure \
to read the precautionary
notices in the supplemental restraint system (See page 60±1).
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5100G±06
51±2
±
POWER STEERING POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help you find the cause of the problem. The numbers \
indicate the likelihood of the
cause in the descending order. Check each part in the order shown. Replace parts if necessary.
Hydraulic Power Steering System:
SymptomSuspect AreaSee page
Hard steering
3. Tires (Improperly inflated)
4. Power steering fluid level (Low)
5. Drive belt (Loose)
6. Front wheel alignment (Incorrect)
7. Steering system joints (Worn)
8. Suspension arm ball joints (Worn)
9. Steering column (Binding)
10.Power steering vane pump AZ Series: 1CD±FTV:
11. Power steering gear28±1
51±4
26±6 ±
26±24 ±
51±9
51±19 51±4
51±36
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gear28±1
26±6 ±
51±4
51±36
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear±
26±24 ±
30±2
51±4
51±36
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering vane pump AZ Series: 1CD±FTV:
4. Power steering gear51±4
±
51±9
51±19 51±4
51±36
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±
POWER STEERING POWER STEERING SYSTEM
51±3
AVENSIS REPAIR MANUAL (RM1018E)
Electronic Power Steering System:
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering system joints (Worn)
4. Suspension arm ball joints (Worn)
5. Steering column (Binding)
6. Steering column (Electric power steering system)
7. Steering gear (torque)28±1
26±6
±
26±24 ±
50±9
51±28
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Steering column (Electric power steering system)
5. Steering gear (torque)28±1
26±6 ±
50±9
51±28
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Steering column (Electric power steering system)
6. Steering gear (torque)±
26±24 ±
30±2
50±9
51±28
Abnormal noise
1. Steering system joints (Worn)
2. Steering column (Electric power steering system)
3. Steering gear (torque)±
50±9
51±28
HINT:
When the problem occurs on the Electric Power Steering system, refer to \
the DI section (See page 05±1042
).
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510DE±02
F40449
R11229
NormalAbnormal
R00427
51±4
±
POWER STEERING POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords, etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
missing chunks from the ribs are found on the belt, it should be
replaced.
2. BLEED POWER STEERING SYSTEM
(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with the stands.
(c) Turn the steering wheel. (1) With the engine stopped, turn the wheel slowly fromlock to lock several times.
(d) Lower the vehicle.
(e) Start the engine. (1) Run the engine at idle for a few minutes.
(f) Turn the steering wheel. (1) With the engine idling, turn the wheel to right full lock
position and keep it there for 2 to 3 seconds, then
turn the wheel to left full lock position and keep it
there for 2 to 3 seconds.
(2) Repeat (1) several times.
(g) Stop the engine.
(h) 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.
(i) Recheck the fluid level.
3. 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:
If the fluidis hot, check that the fluid level is within the HOT LEV-
EL range on the oil reservoir. If the fluid is cold, check that it is
within the COLD LEVEL range.
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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)
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D30364
AttachmentOUT
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 STEERING POWER 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.
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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).
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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 STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
RACK & PINION POWER STEERING GEAR ASSY
COMPONENTS
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D30602
Tie Rod End Sub±assy RHLock 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 STEERING RACK & PINION POWER STEERING GEAR ASSY
51±35
AVENSIS REPAIR MANUAL (RM1018E)
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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.
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