length TOYOTA AVENSIS 2003 Service Manual PDF

D29968
RHD:
LHD:
Fulcrum Length
Fulcrum Length
SST(s)
SST(s)
D29967
RHD:
LHD:
Fulcrum LengthFulcrum
Length
SST(s)
SST(s)
51±44
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
44.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
45. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
46.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
47. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side. 48. CONNECT PRESSURE FEED TUBE ASSY
(a) Using SST(s), connect the pressure feed tube assy.SST 09023±12700
Torque: 41 N
m (414 kgf
cm, 30 ft
lbf)
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).

This torque value is effective when SST(s) is parallel to a
torque wrench.
49. CONNECT STEERING GEAR OUTLET RETURN TUBE
(a) Using SST(s), connect the outlet return tube. SST 09023±12700
Torque: 41 N
m (414 kgf
cm, 30 ft
lbf)
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).

This torque value is effective when SST(s) is parallel to a
torque wrench.
(b) LHD: Install the tube clamp with bolt to the power steering gear
assy.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
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F40053
SST(s)
SST(s)
Fulcrum
LengthHold
Turn
C57755
F400843 mm (0.12 in.) or less SST(s)
±
POWER STEERING STEERING GEAR ASSY
51±31
AVENSIS REPAIR MANUAL (RM1018E)
34. INSTALL STEERING RACK END SUB±ASSY
(a) Using SST(s), hold the steering rack steadily and using
another SST(s), torque the rack end sub±assy.
SST 09922±10010
Torque: 60 N
m (616 kgf
cm, 45 ft
lbf)
NOTICE:
Use SST(s) 09922±10010 in the direction shown in the il-
lustration.
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.)

Perform the same procedure on the other side.
35. 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.
36. INSTALL STEERING RACK BOOT NO.1
HINT:
Perform the same procedure on the other side. 37. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Install a new rack boot No.2 clamp to the rack boot No.2.
(b) Using SST(s), stake the rack boot No.2 clamp as shownin the illustration.
SST 09521±24010
38. INSTALL STEERING RACK BOOT NO.1 CLAMP SST 09521±24010
HINT:
Perform the same procedure on the other side.
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C65369
D30331
Cloth
F09875


D30332
LengthThickness
R10282
Feeler Gauge
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
51±21
AVENSIS REPAIR MANUAL (RM1018E)
(c) Remove the O±ring from the housing sub±assy front.
14. REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using a screwdriver, remove the housing oil seal.
NOTICE:
Be careful not to damage the pump housing.
15. INSPECT VANE PUMP SHAFT AND BUSH IN
HOUSING FRONT
(a) Using a micrometer and a caliper gauge, measure the oil clearance.
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the vane pump assy.
16. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES
(a) Using a micrometer, measure the thickness of the vane pump plates.
Minimum thickness:
1.405 to 1.411 mm (0.05531 to 0.05555 in.)
(b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and vane plate.
Maximum clearance: 0.03 mm (0.0012 in.)
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D30362Inscribed Mark

D30363


F41622
Compressed Air
51±22
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
If it is more than the maximum, replace the vane pump plate
and/or vane pump rotor with the one having the same mark as
stamped on the cam ring. Inscribed mark: 0, 1, 2, 3 or 4
HINT:
There are 5 different marks for vane pump plate.
MarkPart numberLength mm (in.)
044345±0211012.001 to 12.003
(0.47247 to 0.47255)
144345±0212011.999 to 12.000
(0.47240 to 0.47244)
244345±0213011.997 to 11.998
(0.47232 to 0.47236)
344345±0214011.995 to 11.996
(0.47224 to 0.47228)
444345±0215011.993 to 11.994
(0.47216 to 0.47220)
17. INSPECT FLOW CONTROL VALVE ASSY
(a) Coat the flow control valve assy with power steering fluid and check that it falls smoothly into the flow control valve
hole by its own weight.
If necessary, replace the vane pump assy.
(b) Check the flow control valve assy for leakage. Close one
of the holes and apply compressed air of 392 to 490 kPa
(4 to 5 kgf
cm
2, 57 to 71 psi) into the opposite side hole,
and confirm that air does not come out from the end holes.
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D31004
Inscribed Mark
R08702
Vernier Calipers
F42121
SST(s)Oil Seal

D30334
Vinyl Tape
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
51±23
AVENSIS REPAIR MANUAL (RM1018E)
If necessary, replace the flow control valve assy with the one
having the same letter as inscribed on the housing sub±assy
front
Inscribed mark: A, B, C, D, E or F
HINT:
There are 6 different marks for flow control valve assy.
MarkPart number
A44330±05190
B44330±05200
C44330±05210
D44330±05220
E44330±05230
F44330±05240
18. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum free length: 36.9 mm ( 1.453 in.)
If it is less than the minimum, replace the compression spring.
19. INSPECT PRESSURE PORT UNION SUB±ASSY
(a) If the union seat in the pressure port union sub±assy is remarkably damaged, it may cause flui\
d leak- age. Replace the pressure port union sub±assy.
20. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new housing oil seal lip with power steering fluid.
(b) Using SST(s) and a press, install a new housing oil seal.SST 09950±60010 (09951±00280), 09950±70010
(09951±07100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
21. INSTALL W/PULLEY SHAFT SUB±ASSY
(a) Coat inside bushing surface of the housing sub±assy front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub±assy.
NOTICE:
Do not damage the oil seal lip.
HINT:
Tape the shaft before inserting.
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D30335
Inward
Outward

D30336
C70126
F45776
Service Bolt
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
51±25
AVENSIS REPAIR MANUAL (RM1018E)
(b) Coat 10 vane pump plates with power steering fluid.
(c) Install the vane pump plates with the round end facing
outward.
25. INSTALL VANE PUMP SHAFT SNAP RING
(a) Using a screwdriver and a snap ring expander, install a new snap ring to the w/pulley shaft sub±assy.
26. INSTALL VANE PUMP HOUSING SUB±ASSY REAR
(a) Coat a new O±ring with power steering fluid and install it onto the housing sub±assy rear.
(b) Align the straight pin of the housing sub±assy rear with the dents of the cam ring, side plate front and housing
sub±assy front, and install the vane pump housing sub±
assy rear with the 4 bolts.
Torque: 22 N
m (224 kgf
cm, 16 ft
lbf)
27. INSPECT PRELOAD
(a) Check that the pump rotates smoothly without abnormal noise.
(b) Temporarily install the service bolt.
Recommended service bolt:
Thread diameter: 10 mm (0.39 in.)
Thread pitch: 1.25 mm (0.0492 in.)
Bolt length: 50 mm (1.97 in.)
(c) Using a torque wrench, check the pump rotating torque. Rotating torque:
0.27 N
m (2.8 kgf
cm, 2.4 ft
lbf) or less
If the rotating torque is not as specified, check the housing oil
seal.
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D30361
D30580
B
B
B
A
D30581
Fulcrum
Length
SST(s)
51±26
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
28. INSTALL FLOW CONTROL VALVE ASSY
(a) Coat the compression spring and the flow control valve assy with power steering fluid.
(b) Install the compression spring and the flow control valve assy.
(c) Coat a new O±ring with power steering fluid and install it onto the pressure port union sub±assy.
(d) Install the pressure port union sub±assy. Torque: 69 N
m (704 kgf
cm, 51 ft
lbf)
29. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O±ring with power steering fluid, and install it to the su\
ction port union.
(b) Install the suction port union with the bolt. Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
30. INSTALL VANE PUMP ASSY
(a) Install the vane pump assy and vane pump bracket rear with the 4 bolts.
Torque:
Bolt A: 72 N
m (734 kgf
cm, 53 ft
lbf)
Bolt B: 39 N
m (398 kgf
cm, 29 ft
lbf)
31. CONNECT PRESSURE FEED TUBE ASSY
(a) Using SST(s), connect the pressure feed tube assy. SST 09023±12700
Torque: 41 N
m (414 kgf
cm, 30 ft
lbf)
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).

This torque value is effective when SST(s) is parallel to a
torque wrench.
(b) Install the tube clamp with the bolt. Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
32. 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.
33. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
34. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55±46)
35.ADD POWER STEERING FLUID (See page 51±4)
36.BLEED POWER STEERING FLUID (See page 51±4)
37.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
38. INSPECT FLUID LEAK
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C65368
C65369
D30331
Cloth
F09875


D30332
LengthThickness
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±11
AVENSIS REPAIR MANUAL (RM1018E)
16. REMOVE VANE PUMP SIDE PLATE FRONT
(a) Remove the side plate front from the housing sub±assy
front.
(b) Remove the O±ring from the side plate front.
(c) Remove the O±ring from the housing sub±assy front.
17. REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using a screwdriver, remove the housing oil seal.
NOTICE:
Be careful not to damage the pump housing.
18. INSPECT VANE PUMP SHAFT AND BUSH IN HOUSING FRONT
(a) Using a micrometer and a caliper gauge, measure the oil clearance.
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the vane pump assy.
19. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES
(a) Using a micrometer, measure the thickness of the vane
pump plates.
Minimum thickness:
1.405 to 1.411 mm (0.05531 to 0.05555 in.)
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R10282
Feeler Gauge
D30362Inscribed Mark
F41493


F41622
Compressed Air
51±12
±
POWER STEERING VANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and vane plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the vane pump plate
and/or vane pump rotor with the one having the same mark as
stamped on the cam ring. Inscribed mark: 0, 1, 2, 3 or 4
HINT:
There are 5 different marks for vane pump plate.
MarkPart numberLength mm (in.)
044345±0211012.001 to 12.003
(0.47247 to 0.47255)
144345±0212011.999 to 12.000
(0.47240 to 0.47244)
244345±0213011.997 to 11.998
(0.47232 to 0.47236)
344345±0214011.995 to 11.996
(0.47224 to 0.47228)
444345±0215011.993 to 11.994
(0.47216 to 0.47220)
20. INSPECT FLOW CONTROL VALVE ASSY
(a) Coat the flow control valve assy with power steering fluid and check that it falls smoothly into the flow control valve
hole by its own weight.
If necessary, replace the vane pump assy.
(b) Check the flow control valve assy for leakage. Close one of the holes and apply compressed air of 392 to 490 kPa
(4 to 5 kgf
cm
2, 57 to 71 psi) into the opposite side hole,
and confirm that air does not come out from the end holes.
http://vnx.su

D31004
Inscribed Mark
R08702
Vernier Calipers
F08480
SST(s)
Oil Seal

D30334
Vinyl Tape
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±13
AVENSIS REPAIR MANUAL (RM1018E)
If necessary, replace the flow control valve assy with the one
having the same letter as inscribed on the housing sub±assy
front.
Inscribed mark: A, B, C, D, E or F
HINT:
There are 6 different marks for flow control valve assy.
MarkPart number
A44330±05130
B44330±05140
C44330±05150
D44330±05160
E44330±05170
F44330±05180
21. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum free length: 36.9 mm ( 1.453 in.)
If it is less than the minimum, replace the compression spring.
22. INSPECT PRESSURE PORT UNION SUB±ASSY
(a) If the union seat in the pressure port union sub±assy is remarkably damaged, it may cause flui\
d leak- age. Replace the pressure port union sub±assy.
23. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new housing oil seal lip with power steering fluid.
(b) Using SST(s) and a press, install a new housing oil seal.SST 09950±60010 (09951±00280), 09950±70010
(09951±07100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
24. INSTALL W/PULLEY SHAFT SUB±ASSY
(a) Coat inside bushing surface of the housing sub±assy front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub±assy.
NOTICE:
Do not damage the oil seal lip.
HINT:
Tape the shaft before inserting.
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