steering TOYOTA AVENSIS 2003 Service Owner's Guide

±
PREPARATION MANUAL TRANSMISSION/TRANSAXLE
02±41
AVENSIS REPAIR MANUAL (RM1018E)
09608±32010Steering Knuckle Oil Seal
ReplacerFRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09628±62011Boll Joint PullerMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09670±00010Front Crossmember Guide ToolMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
09930±00010Drive Shaft Nut ChiselMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
09950±70010Handle SetFRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
(09951±07200)Handle 200FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
Recomended Tools
09011±12301Socket Wrench 30 mmMANUAL TRANSAXLE
ASSY(1AZ±FE/1AZ±FSE)
MANUAL TRANSAXLE
ASSY(1CD±FTV)
MANUAL TRANSAXLE
ASSY(1ZZ±FE/3ZZ±FE)
FRONT DIFFERENTIAL OIL
SEAL(C50/C250)
FRONT DIFFERENTIAL OIL
SEAL(E354/E357)
http://vnx.su

022KE±01
±
PREPARATION POWER STEERING
02±45
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING
PREPARATION
SST
09023±12700Union Nut Wrench 17mmRACK & PINION POWER STEERING
GEAR ASSY
VANE PUMP ASSY(1CD±FTV)
09249±63010Torque Wrench AdaptorVANE PUMP ASSY(AZ Series)
09521±24010Rear Axle Shaft PullerSTEERING GEAR ASSY
RACK & PINION POWER STEERING
GEAR ASSY
09612±00012Rack & Pinion Steering Rack
Housing StandSTEERING GEAR ASSY
09616±00011Steering Worm Bearing Adjusting
SocketSTEERING GEAR ASSY
09630±00014Power Steering Gear Housing
Overhaul Tool SetVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
(09631±00132)Vane Pump BracketVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
09922±10010Variable Open WrenchSTEERING GEAR ASSY
09950±60010Replacer SetVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
(09951±00280)Replacer 28VANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
09950±70010Handle SetVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
(09951±07100)Handle 100VANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
http://vnx.su

02±46
±
PREPARATION POWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09025±00010Torque Wrench (30 kgf±cm)STEERING GEAR ASSY
RACK & PINION POWER STEERING
GEAR ASSY
VANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
09090±04020Engine Sling DeviceSTEERING GEAR ASSY
RACK & PINION POWER STEERING
GEAR ASSY
09905±00012Snap Ring No.1 ExpanderVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
Equipment
Caliper gaugeVane pump assy
Belt tension gaugeVane pump assy
Vernier calipersVane pump assy
Feeler gaugeVane pump assy
MicrometerVane pump assy
Torque wrench
http://vnx.su

022L8±01
02±26
±
PREPARATION REAR SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION
PREPARATION
SST
09610±20012Pitman Arm PullerREAR SUSPENSION ARM ASSY
NO.1 LH
LOWER CONTROL ARM ASSY LH
09628±62011Boll Joint PullerREAR SUSPENSION ARM ASSY
NO.1 LH
09632±36010Steering Vane Pump Bearing
ReplacerREAR SUSPENSION ARM ASSY
NO.1 LH
09727±30021Coil Spring CompressorREAR SHOCK ABSORBER WITH
COIL SPRING
(09727±00010)Bolt SetREAR SHOCK ABSORBER WITH
COIL SPRING
(09727±00021)Arm SetREAR SHOCK ABSORBER WITH
COIL SPRING
(09727±00031)CompressorREAR SHOCK ABSORBER WITH
COIL SPRING
09950±40011Puller B SetREAR SUSPENSION ARM ASSY
NO.1 LH
(09951±04010)Hanger 150REAR SUSPENSION ARM ASSY
NO.1 LH
(09952±04010)Slide ArmREAR SUSPENSION ARM ASSY
NO.1 LH
(09953±04030)Center Bolt 200REAR SUSPENSION ARM ASSY
NO.1 LH
(09954±04020)Arm 100REAR SUSPENSION ARM ASSY
NO.1 LH
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022JS±01
02±44
±
PREPARATION STEERING COLUMN
AVENSIS REPAIR MANUAL (RM1018E)
STEERING COLUMN
PREPARATION
SST
09616±00011Steering Worm Bearing Adjusting
SocketSTEERING COLUMN ASSY
09950±50013Puller C SetSTEERING COLUMN ASSY
(09951±05010)Hanger 150STEERING COLUMN ASSY
(09952±05010)Slide ArmSTEERING COLUMN ASSY
(09953±05020)Center Bolt 150STEERING COLUMN ASSY
(09954±05021)Claw No.2STEERING COLUMN ASSY
Recomended Tools
09025±00010Torque Wrench (30 kgf±cm)STEERING COLUMN ASSY
09042±00010Torx Socket T30STEERING COLUMN ASSY
09070±20010Moulding RemoverSTEERING COLUMN ASSY
POWER STEERING ECU ASSY
EQUIPMENT
Torque wrench
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030MV±02
03±42
±
SERVICE SPECIFICATIONS BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Wheel nut1031,05076
Brake line union nut 10 mm
14 mm15
29155
29611
21
Brake booster clevis lock nut1919414
Brake master cylinder sub±assy x Brake booster assy2020415
Charcoal canister bracket x Body5.45548 in.
lbf
Brake booster assy x Body131309
Brake pedal support x Instrument panel reinforcement2424117
Brake pedale support x Brake pedal3737527
Brake pedale support x Body131309
Brake tube clamp x body5.45548 in.
lbf
Vacuum pump x Engine2121415
Vacuum pump union nut1414010
Vacuum pump check valve sub±assy x End cover7421454
Vacuum pump end cover x vacuum pump housing7.88069 in.
lbf
Front disc brake bleeder plug101027
Front brake cylinder mounting x Steering knuckle1021,04075
Front disc brake cylinder x Front disc brake cylinder mounting3030622
Front disc brake caliper x Flexible hose2929621
Rear disc brake bleeder plug101027
Rear disc brake cylinder mounting x Steering knuckle4747534
Rear disc brake cylinder x Rear disc brake cylinder mounting3030622
Rear disc brake caliper x Flexible hose2929621
Brake actuator x Brake actuator bracket
w/o VSC:
w/ VSC:7.0
4.771
4862 in.
lbf
42 in.
lbf
Front speed sensor wire harness clamp x shock absorber2929621
Brake actuator bracket x Body1919514
Front speed sensor x Steering knuckle8.08271 in.
lbf
Yawrate sensor bracket set bolt2121415
Yawrate sensor x Yawrate sensor bracket66153 in.
lbf
Yawrate sensor bracket x Body2121415
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030L1±03
±
SERVICE SPECIFICATIONS CLUTCH
03±55
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH
SERVICE DATA
Pedal height from asphalt sheet
LHD steering position type
1CD±FTV engine type w/ intercooler
Others
154.0 ± 164.0 mm (6.063 ± 6.457 in.)
139.6 ± 149.6 mm (5.496 ± 5.890 in.)
Pedal height from asphalt sheet
RHD steering position type 1CD±FTV engine type w/ intercooler
Others
158.4 ± 168.4 mm (6.236 ± 6.630 in.)
148.4 ± 158.4 mm (5.843 ± 6.236 in.)
Clutch pedal free play5.0 ± 15.0 mm (0.197 ± 0591 in.)
Clutch pedal push rod play at pedal top1.0 ± 5.0 mm (0.039 ± 0.197 in.)
Slotted spring pin protrusion1.5 ± 3.5 mm (0.059 ± 0.138 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch disc rivet head depth Maximum0.3 mm (0.012 in.)
Clutch disc assy runout Minimum0.8 mm (0.031 in.)
Diaphragm spring finger wearMaximum depth:
Maximum width:0.5 mm (0.020 in.)
6.0 mm (0.236 in.)
Flywheel sub±assy runout Maximum0.1 mm (0.004 in.)
Diaphragm tip alignment Maximum0.5 mm (0.020 in.)
http://vnx.su

030KC±06
03±40
±
SERVICE SPECIFICATIONS DRIVE SHAFT / PROPELLER SHAFT / AXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Front wheel set nut1031,05076
Rear wheel set nut1031,05076
Manual transaxle oil drain plug C50/C250:
E354/E357:39
49400
50029
36
Lower ball joint assy front x Suspension arm sub±assy lower No.18990866
Tie rod end sub±assy x Steering knuckle4950036
Flexible hose and speed sensor front x Shock absorber assy front1919414
Speed sensor front x Steering knuckle8.08271 in.
lbf
Front stabilizer link assy x Shock absorber assy front7475555
Front axle hub nut2162,200159
Disc brake dust cover front x Steering knuckle8.38573 in.
lbf
Lower ball joint assy front x Steering knuckle1031,05076
Front axle assy x Shock absorber assy front2202,243162
Front disc brake caliper assy x Steering knuckle1021,04075
Automatic transaxle fluid drain plug4950036
Drive shaft bearing case x Bearing bracket6465047
Rear axle hub & bearing assy x Rear axle carrier sub±assy5657141
Rear axle carrier sub±assy x Back plate assy1401,428103
Rear axle carrier sub±assy x Skid control sensor wire5.05144 in.
lbf
Rear disk brake caliper assy x Rear axle carrier sub±assy4747534
Rear axle carrier sub±assy x Upper control arm assy7475555
Rear axle carrier sub±assy x Lower control arm assy ball joint side:
member side:60
105612
1,07144
77
Rear axle carrier sub±assy x Rear suspension arm assy ball joint side: member side:105741,071 75577
55
http://vnx.su

031DY±01
03±4
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE CONTROL SYSTEM
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Power steering oil pressure switch
Voltage EMPS ± E2 Not spin the steering wheel at engine idling
Spin the steering wheel at engine idling
8 to 14 V
0 to 1.5 V
Idle air control valve
Movement Ignition switch ON
Half open  fully close  fully open  half open
Mass air flow meter
Resistance 4 (THA) ± 5 (E2)
at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
13.6 to 18.4 k

2.21 to .69 k

0.49 to 0.67 k

Camshaft timing oil control valve assy
Resistance at 20
C (68
F)
6.9 to 7.9

Throttle position sensor
Resistance VC ± E2
2.5 to 6.0 k

E.F.I. Engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k

0.310 to 0.326 k

Knock control sensor
Resistance Approx. 20
C (68
F)
120 to 280 k

1AZ±FE/1AZ±FSE:
Power steering oil pressure switch
Voltage PSW ± E2
Not spin the steering wheel at engine idling
Spin the steering wheel at engine idling
9 to 14 V
0 to 3 V
Idle air control valve
Movement Ignition switch ON
Half open  fully close  fully open  half open
Throttle body assy (1AZ±FSE)
Throttle valve opening percentage
Idle speed
60 % or more
700  50 rpm
Accelerator pedal position sensor (1AZ±FSE)
Voltage ACCEL POS Released
Depress
ACCEL POS #2 Released Depress
0.5 to 1.1 V
2.6 to 4.5 V
1.2 to 2.0 V
3.4 to 5.3 V
Mass air flow meter
Resistance 4 (THA) ± 5 (E2) at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
13.6 to 18.4 k

2.21 to .69 k

0.49 to 0.67 k

Camshaft timing oil control valve assy
Resistance at 20
C (68
F)
6.9 to 7.9

Throttle position sensor (1AZ±FE)
Resistance VC ± E2
2.5 to 5.0 k

Throttle body assy (1AZ±FSE)
Resistance 2 (M+) ± 1 (M±)
0.3 to 100
at 20
C (68
F)
E.F.I. Engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k

0.310 to 0.326 k

Knock control sensor
Resistance Approx. 20
C (68
F)
120 to 280 k

http://vnx.su

031DZ±02
03±6
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle position sensor x Throttle body assy2.02018 in.
lbf
ISC valve x Throttle body assy3.73833 in.
lbf
Accelerator control cable bracket x Throttle body assy1313310
Throttle body assy x Intake manifold3030622
Throttle body bracket x Cylinder block sub±assy (1ZZ±FE)3030622
Manifold stay No. 2 x Throttle body assy (M/T)1313310
Accelerator control cable assy x Accelerator control cable bracket131299
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold3030622
Accelerator control cable assy x Throttle body assy131299
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
Intake manifold x Cylinder head sub±assy3030622
Variable resister x Body (Leaded gasoline (Steering position LHD))5.05144 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold9.09280 in.
lbf
Throttle body bracket x Throttle body assy2121015
Throttle body bracket x Cylinder head sub±assy2121015
Ground terminal x Throttle body bracket8.48674 in.
lbf
Wire harness protector x Throttle body bracket8.48674 in.
lbf
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Accelerator pedal x Body5.45548 in.
lbf
Knock control sensor x Cylinder block2020415
Engine cover bracket x Cylinder head3838828
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Intake shutter assy x Intake air connector2121415
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Air tube No. 2 x Transmission2525518
Air tube No. 1 x Air tube No. 22525518
Camshaft position sensor x Camshaft oil seal retainer8.89079 in.
lbf
Return tube sub±assy x Engine hanger No. 19.09280 in.
lbf
Crankshaft position sensor x Oil pump assy8.89079 in.
lbf
ECM x Body5.55649 in.
lbf
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