wheel torque TOYOTA AVENSIS 2003 Service Repair Manual

5000C±14
±
STEERING COLUMN STEERING SYSTEM
50±1
AVENSIS REPAIR MANUAL (RM1018E)
STEERING SYSTEM
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Be careful to replace the parts properly because they could affect the performance of the steering sys-
tem 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).
3. HANDLING PRECAUTIONS ON STEERING COLUMN
(a) Do not give an impact to the steering column assy, especially the motor and the torque sensor. If a great impact is given (dropping it to the floor, etc.), replace it with a new one.
(b) When removing the steering column assy, do not pull the harness.
(c) When having replaced the steering column assy and/or the ECU, calibrate the \
zero point of the steer- ing torque sensor.
(d) In the case of disconnecting a connector related to the power steering sys\
tem, turn the ignition switch ON, set the steering wheel in the straight±ahead position and turn th\
e ignition switch OFF before dis-
connecting the connector.
(e) In the case of connecting a connector related to the power steering system, make sure that the ignit\
ion switch is OFF at first. After connecting the connector, set the steering wheel assy in the straight±ahead
position, and then turn the ignition switch ON.
NOTICE:
Never turn on the ignition switch when the steering wheel assy is set in orde\
r than the straight±ahead
position.
(f) If the above operation is not done, the zero point of the steering torque \
sensor is shifted away from the proper position, making difference in the steering effort between right and left. If this happens, per-
form the zero point calibration of the steering torque sensor (See page 05±1042).
http://vnx.su

±
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
).
http://vnx.su

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).
http://vnx.su



D30705
LHD:
A
B
RHD:
Matchmarks
Matchmarks
A
B
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±45
AVENSIS REPAIR MANUAL (RM1018E)
50. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
51.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
52. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
53. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
54. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
55. INSTALL STEERING INTERMEDIATE SHAFT ASSYNO.2
(a) Align the matchmarks on the intermediate shaft assy No.2 and the intermediate shaft.
(b) Install the bolt B and tighten the bolt A. Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
56.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
57. INSTALL CYLINDER HEAD COVER SUB±ASSY
58.ADD POWER STEERING FLUID (See page 51±4)
59.BLEED POWER STEERING FLUID (See page 51±4)
60.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
61. INSPECT FLUID LEAK
62.INSPECT HOOD SUB±ASSY (See page 75±2)
63.ADJUST HOOD SUB±ASSY (See page 75±2)
64.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
65. INSTALL ENGINE UNDER COVER LH
66. INSTALL ENGINE UNDER COVER RH
67.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
http://vnx.su

510DJ±02
D25320
No.1 Engine HangerNo.2 Engine Hanger
Front:Rear:
51±28
±
POWER STEERING 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±27).
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
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.
10. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
11.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
12. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.
13.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
14. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
15. REMOVE HOOD SUB±ASSY
16. REMOVE CYLINDER HEAD COVER SUB±ASSY
17. SUSPEND ENGINE ASSEMBLY
(a) Remove the 2 PCV hoses.
(b) Install the 2 engine hangers in the correct direction.No.1 engine hanger: 12281±22021
No.2 engine hanger: 12281±15040
Bolt: 90512±B1016
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(c) Attach the engine chain hoist to the hangers.
CAUTION:
Do not attempt t hang the ingine by hooking the chain to
any other part.
18.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 51±36)
19. REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1
http://vnx.su

±
POWER STEERING STEERING GEAR ASSY
51±33
AVENSIS REPAIR MANUAL (RM1018E)
46.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
47. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
48.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
49. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.
50. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
51.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
52. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
53. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
54. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
55.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
56.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
57. INSTALL CYLINDER HEAD COVER SUB±ASSY
58.INSPECT HOOD SUB±ASSY (See page 75±2)
59.ADJUST HOOD SUB±ASSY (See page 75±2)
60.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
61. INSTALL ENGINE UNDER COVER LH
62. INSTALL ENGINE UNDER COVER RH
63.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
http://vnx.su

±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±17
AVENSIS REPAIR MANUAL (RM1018E)
37. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No.1 with the clip.
NOTICE:
Take care not to spill fluid on the V belt.
38. INSTALL FAN AND GENERATOR V BELT
1AZ±FE: (See page 14±105)
1AZ±FSE: (See page 14±185)
39. INSTALL ENGINE UNDER COVER RH
40. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
41.ADD POWER STEERING FLUID (See page 51±4)
42.BLEED POWER STEERING FLUID (See page 51±4)
43.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
44. INSPECT FLUID LEAK
http://vnx.su

6009O±06
H42639N
m (kgf
cm, ft
lbf): Specified torque Torx Screw
Steering Column Cover
w/Instrument Cluster Fin-
ish Panel Assy
Torx Screw
Horn Button Assy
Steering Column Cover Assy Spiral Cable Sub±Assy
Steering Wheel Assy
50 (510, 37)
Instrument Panel Airbag Assy
Instrument Panel Hole Cover
8.8 (90, 78 in.

lbf)8.8 (90, 78 in.
lbf)
60±16
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
STEERING WHEEL ASSY
COMPONENTS
http://vnx.su

H43003
H42615
60±18
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
4. INSTALL HORN BUTTON ASSY
(a) Support the horn button assy with the hand as shown in the illustration.
(b) Connect the airbag connectors.
(c) Connect the horn connector.
(d) Confirm that the circumference groove of the torx screw fits in the screw case, and place the horn button assy onto
the steering wheel assy.
(e) Using a torx socket wrench (T 30), install the 2 screws. Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
5.INSPECT HORN BUTTON ASSY (See page 60±11)
(a) Do a visual check which includes the following items with the horn button assy installed in the vehicle:
Cuts, minute cracks or marked discoloration on the horn
button assy top surface and in the grooved portion.
6.INSPECT SRS WARNING LIGHT (See page 05±1184)
http://vnx.su

B66038
Heater to Register Duct No.2Instrument Panel Lower AssyCowl Side Trim
Board RHFront Door
Scuff Plate
RH
Floor Shift
Shift Lever
Knob Sub±assy
Console Panel
Sub±assy Upper
Console Panel Sub±assy LowerConsole Box Assy RR
Front Door
Scuff Plate LH Cowl Side Trim
Board LH
Instrument Panel Airbag Assy Console Rear End
Panel
Radio Receiver
Assembly w/ Bracket
Windshield
Wiper Switch Assy
Instrument Panel
Hole Cover Head lamp
Dimmer Switch Assy
Instrument Panel Under
Cover Sub±assy No.2
Horn Button Assy
Steering Wheel Assy
Instrument Panel Under Cover
Sub±assy No.1
H
N´m (kgf´cm, ft´lbf) : Specified torque M/T Transaxle:
A/T Transaxle:
A/T Only:
M/T Only:
50 (510, 37)
8.8 (90, 78 in.´lbf)
orEF
D
B
B or
EF
I
or
EF
or
EF
H
HH
H
H
HH
H
H
CC
CC
H
H Console Panel
Sub±assy Upper
18 (184, 13)
18 (184, 13)
71±8
±
INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su