power steering TOYOTA AVENSIS 2003 Service Workshop Manual

±
COOLINGWATER PUMP ASSY(1CD±FTV)
16±49
AVENSIS REPAIR MANUAL (RM1018E)
41.SET NO. 1 CYLINDER TO TDC/COMPRESSION
SST09960±10010 (09962±01000, 09963±01000)
42.INSTALL TIMING BELT(See page 14±307)
43.CHECK VALVE TIMING(See page 14±307)
44.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
45.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
46.INSTALL TIMING BELT GUIDE(See page 14±307)
47.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
48.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
49.INSTALL IDLER PULLEY SUB±ASSY(See page 11±69)
50.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
51.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
52.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
53.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
54.INSTALL INJECTOR DRIVER(See page 11±69)
55. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
56. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
57.ADD ENGINE COOLANT(See page 16±44)
58.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
59.CHECK FOR FUEL LEAKS(See page 11±60)
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170FP±01
SST
A09582
17±22
±
LUBRICATIONOIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL(See page 17±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER(See page 14±307)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17.REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22.REMOVE TIMING BELT IDLER SUB±ASSY NO.2(See page 14±307)
23.REMOVE CRANKSHAFT TIMING PULLEY
(a)If the timing pulley can not be removed by hand, use SSTto remove the pulley.
SST09950±50013 (09951±05010, 09952±05010, 09953±05010, 09953±05020, 09954±05021)
24.REMOVE GENERATOR ASSY(See page 19±29)
25. REMOVE TIMING BELT IDLER SUB±ASSY NO.1
26. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the 2 bolts and the V±ribbed belt tensioner.
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SST
A09583
Inward
Angle Sensor
±
LUBRICATIONOIL PUMP ASSY(1CD±FTV)
17±29
AVENSIS REPAIR MANUAL (RM1018E)
47.INSTALL CRANKSHAFT TIMING PULLEY
(a)Align the keyway of the timing pulley with the key located
on the camshaft, slide the pulley into place.
(b)Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
SST09223±46011
48.INSTALL TIMING BELT IDLER SUB±ASSY NO.2 Torque: 47 N
m (479 kgf
cm,35 ft
lbf)
49.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
50.INSTALL TIMING BELT(See page 14±307)
51.CHECK VALVE TIMING(See page 14±307)
52.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
53.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
54.INSTALL TIMING BELT GUIDE(See page 14±307)
55.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
56.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
57.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
58. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59. INSTALL IDLER PULLEY SUB±ASSY
60.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
61. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
62.INSTALL INJECTOR DRIVER (See page 14±307)
63. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
64. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
65.ADD ENGINE OIL(See page 17±30)
66. CHECK FOR ENGINE OIL LEAKS
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F44615
Rack & Pinion Power
Steering Gear Assy
49 (500, 36)
Tie Rod End Sub±assy LH
Front Stabilizer Link Assy RH
Transverse Engine
Engine Mounting Insulator
Front Stabilizer Link Assy LH
Front Suspension
Crossmember Sub±assy
Front Suspension
Member Body Mounting
Stopper FR
133 (1,360, 98)
137 (1,400, 101)
Body Mounting Stopper Rear
52 (530, 38)
80 (816, 59)
74 (755, 55)
Front Suspension
Member Brace
Rear LH
80 (816, 59)
133 (1,360, 98)
Cotter Pin
49 (500, 36)
89 (908, 66)
Front Suspension Arm
Sub±assy Lower No.1 LH
80 (816, 59)
133 (1,360, 98)
80 (816, 59)
Front Suspension
Member Brace
Rear RH
133 (1,360, 98)
137 (1,400, 101)
N
m (kgf
cm, ft
lbf) : Specified torque

Nblt

Non±reusable part

Engine Mounting Member
Sub±assy Center
96 (979, 71)
±
FRONT SUSPENSION FRONT SUSPENSION
26±3
AVENSIS REPAIR MANUAL (RM1018E)
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F45154
Rack & Pinion
Power Steering Gear AssyTie Rod End
Sub±assy LH
Front Stabilizer Link
Assy LH
Stabilizer Bar Front
Front Stabilizer Link
Assy RH
Front Suspension Arm
Sub±assy Lower No.1 RH
Front Suspension
Member Brace
Rear RH Front Stabilizer
Bar Bush No.1
Front Suspension
Crossmember Sub±assy
Front Suspension
Arm Sub±assy
Lower No.1 LH
Body Mounting
Stopper Rear
Front Suspension
Member Body
Mounting Stopper FR
Front Suspension
Member Brace Rear LH
Cotter Pin


89 (908, 66)
133 (1,360, 98)
49 (500, 36)
74 (755, 55)
80 (816, 59)
133 (1,360, 98)
74 (755, 55)
49 (500, 36)
80 (816, 59)
19 (194, 14)
19 (194, 14)
133 (1,360, 98)
80 (816, 59)
133 (1,360, 98)
80 (816, 59)
19 (194, 14)
49 (500, 36)
74 (755, 55)
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part


5.4 (55, 48 in.
lbf)w/ HID:
HID Height
Control Sensor
Front Stabilizer
Bracket No.1 RH
Front Stabilizer
Bracket No.1 LH
96 (979, 71)
80 (816, 59)
52 (530, 38)
±
FRONT SUSPENSION FRONT SUSPENSION
26±5
AVENSIS REPAIR MANUAL (RM1018E)
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260DQ±01
F13686
C80293
26±16±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)
REPLACEMENT
HINT:

COMPONENTS: See page 26±2

Replace the RH side (Engine: 1AZ) by the same procedures as the LH (A\
TM) side.

Replace the RH side (Engine: 1ZZ) by the same procedures as the LH (M\
TM) side.
1. REMOVE FRONT WHEELS
2. SEPARATE FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the stabilizer bar link fromthe shock absorber.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Separate the RH side by the same procedures as the LH side.
4.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
5. SEPARATE TIE ROD END SUB±ASSY RH SST 09628±62011
HINT:
Separate the RH side by the same procedures as the LH side.
6. SEPARATE FRONT SUSPENSION ARM SUB±ASSYLOWER NO.1 LH
(a) Remove the bolt and 2 nuts, and separate the front sus- pension arm sub±assy lower No.1 from the lower ball
joint.
7. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Separate the RH side by the same procedures as the LH side.
8. SEPARATE RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
9. SUSPEND ENGINE ASSY
(a)U341E: See page 40±11
(b)U241E: See page 40±25
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C95318
C87504
C86742
AA
AAB
B
C95317
AA
A
B
26±18
±
FRONT SUSPENSIONFRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH(ATM)
AVENSIS REPAIR MANUAL (RM1018E)
14.TEMPORARILY TIGHTEN FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a)Install the lower suspension arm sub±assy lower No.1
LH, and temporarily tighten the 2 bolts and nut.
15.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY
(a)Support the front suspension crossmember sub±assy with a transmission jack.
(b)Install the 2 front suspension member body mounting stoppers front and 2 nuts.
Torque: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
(c)Connect the transverse engine engine mounting insula- tor and engine mounting member sub±assy center to the
front suspension crossmember sub±assy.
(d)Install the 3 bolts and 3 nuts. Torque:
Bolt A: 52 N
m (530 kgf
cm, 38 ft
lbf)
Bolt B: 96 N
m (979 kgf
cm, 71 ft
lbf)
(e)w/ HID: Connect the height control sensor (Front) connector.
16.INSTALL FRONT SUSPENSION ME MBER BRACE
REAR LH
(a)Install the front suspension member body mounting stop- per rear to the front suspension member brace rear LH.
(b)Install the 4 bolts and front suspension member brace rear LH.
Torque:
Bolt A: 80 N
m (816 kgf
cm, 59 ft
lbf)
Bolt B: 133 N
m (1,360 kgf
cm, 98 ft
lbf)
17.INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
18.CONNECT RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
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SA0028
ABFront AB
A: Inside
B: Outside
Z03382
Alignment
Tester Gauge
±
FRONT SUSPENSION FRONT WHEEL ALIGNMENT
26±7
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully and measure the turning
angle.
Wheel turning angle:
(Normal package)
Inside wheel
 17'  2 
\b
  \b

 47'  2 
\f
  \b\b
Outside wheel: Reference32 52'  \b
\f
315'  \b
\b
(Rough road package)
Inside wheel
 42'  2 
\f  \b
 09'  2  
  \b\b
Outside wheel: Reference33 16'  \b\f
3138'   \b
*1: Electric motor power steering models
*2: Oil pressure power steering models
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION
(a) Install the camber±caster±kingpin gauge or position the vehicle on the wheel alignment tester.
(b) Inspect the camber, caster and steering axis inclination.
Camber, caster and steering axis inclination:
(Normal package)
Camber
Right±left error±034'  45' (±0.57   0.75 )
45' (0.75 ) or less
Caster
Right±left error\b54'  45' (2.90   0.75 )
45' (0.75 ) or less
Steering axis inclination
Right±left error\b27'  45' (12.45   0.75 )
45' (0.75 ) or less
(Rough road package)
Camber
Right±left error±019'  45' (±0.32   0.75 )
45' (0.75 ) or less
Caster
Right±left error\b40'  45' (2.67   0.75 )
45' (0.75 ) or less
Steering axis inclination
Right±left error56'  45' (11.93   0.75 )
45' (0.75 ) or less
If the caster and steering axis inclination are not within the spe-
cified values, after the camber has been correctly adjusted, re-
check the suspension parts for damaged and/or worn out parts.
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2600P±03
F44620
G21679
26±26
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
STABILIZER BAR FRONT
REPLACEMENT
HINT:
COMPONENTS: See page 26±2
1. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and front stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut,use a hexagon wrench
(6 mm) to hold the stud.
3. REMOVE FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side. 4. INSPECT FRONT STABILIZER LINK ASSY LH
(a) As shown in the illustration, flip the ball joint stud back andforth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate
of 3 ± 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
5.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
6. SEPARATE TIE ROD END SUB±ASSY RH
SST 09628±62011
HINT:
Separate the RH side by the same procedures as the LH side.
7.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
8. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Separate the RH side by the same procedures as the LH side.
9. SEPARATE RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
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F45155
A
B
F44620
26±28
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
21. INSTALL FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID: Install the front stabilizer bracket No.1 RH and the height
control sensor (Front) with the 3 bolts.
Torque:
Bolt A: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
Bolt B: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b) w/o HID: Install the front stabilizer bracket No.1 RH with the 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
22.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
23.INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
24. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
25. INSTALL RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
26.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
27. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
28.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
29. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side.
30. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the 2 nuts.Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
31. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
32. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
33.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
34.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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