length TOYOTA AVENSIS 2003 Service Manual PDF

D30335
Inward
Outward

D30336
C70126
C53369
Service Bolt
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±15
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.
28. 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.
29. 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)
30. 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.
31. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Coat a new O±ring with power steering fluid and install it to the oil\
pressure switch.
(b) Install the oil pressure switch onto the vane pump assy. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
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F42475
F40330
A
SST(s)
BFulcrum Length
F41596
Pressure Feed
Tube Assy
Stopper
51±16
±
POWER STEERING VANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
32. 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)
33. 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)
34. INSTALL PUMP BRACKET REAR
(a) Install the vane pump bracket rear with the bolt. Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
HINT:
Make sure that the stopper of the bracket touches the vane pump body, then torque the bolt.
35. INSTALL VANE PUMP ASSY
(a) Temporarily tighten the bolt A to the vane pump assy.
(b) Install the vane pump assy and the bolt B.Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
(c) Using SST(s) and a deep socket (14 mm), tighten the bolt
A.
SST 09249±63010
Torque: 26 N
m (264 kgf
cm, 19 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.
(d) Connect the connector to the oil pressure switch.
36. CONNECT PRESSURE FEED TUBE ASSY
(a) Install the pressure feed tube assy and gasket to the vane pump assy with the union bolt.
HINT:
Make sure the stopper of the pressure feed tube assy touches
the pump housing front as shown in the illustration.
(b) Using a spanner (27 mm) to hold the pressure port union, torque the union bolt.
Torque: 52 N
m (525 kgf
cm, 38 ft
lbf)
(c) Install the pressure feed tube assy with bolt to the pump bracket rear.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
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B70206
LockUnlock
45

B66570
Protrusion Part
Front
Front
Mark
Protrusion Part
B66568Lock
Unlock
45

±
SEAT BELT REAR SEAT BELT (LIFTBACK MODELS)
61±21
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check the degree of tilt when the belt begins to lock the
ELR.
NOTICE:
Do not disassemble the retractor.
(1) Check that the belt does not lock within 15
of tilt in
all directions but locks with over 45
of tilt when
gently moving the retractor.
If operation is not as specified, replace the belt assy.
(c) Install the belt with the bolt on the floor anchor side. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
(d) Check the ELR lock.
NOTICE:
The check should be performed with the a ssembly
installed. (1) Check that the belt locks by pulling it out quickly af-ter installation.
HINT:
The seat belt does not lock when it is pulled out to a length of
955 mm (37.60 in.) or less.
If operation is not as specified, replace the belt assy.
(e) Check the fastening function of the child restraint system.
NOTICE:
The check should be performed with the a ssembly
installed. (1) Check that the belt cannot be pulled out any more
but rewinds after being pulled out fully.
(2) Check that the belt can be pulled out and rewound after the belt has been fully rewound.
If operation is not as specified, replace the belt assy.
17. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY
INNER
(a) Install the floor anchor and belt with the bolt as shown in the illustration.
Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
NOTICE:
Makesure that the anchor part does not run onto the protru-
sion part of the floor panel.
18. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER
(a) Install the belt with the bolt on the retractor side.
Torque:
7.5 N
m (76.5 kgf
cm, 66 in.
lbf) for front bolt
42 N
m (430 kgf
cm, 31 ft
lbf) for upper bolt
(b) Check the degree of tilt when the belt begins to lock the
ELR.
NOTICE:
Do not disassemble the retractor.
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B70205Lock
Unlock
45

61±16
±
SEAT BELT REAR SEAT BELT (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Install the belt with the bolt on the retractor side. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
(b) Check the degree of tilt when the belt begins to lock the ELR.
NOTICE:
Do not disassemble the retractor. (1) Check that the belt does not lock within 15
of tilt in
all directions but locks with over 45
of tilt when
gently moving the retractor.
If operation is not as specified, replace the seat belt assy.
(c) Install the belt with the bolt on the floor anchor side. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
(d) Check the ELR lock.
NOTICE:
The check should be performed with the a ssembly
installed. (1) Check that the belt locks by pulling it out quickly af-
ter installation.
HINT:
The seat belt does not lock when it is pulled out to a length of
955 mm (37.60 in.) or less.
If operation is not as specified, replace the belt assy.
(e) Check the fastening function of the child restraint system.
NOTICE:
The check should be performed with the a ssembly
installed.
(1) Check that the belt cannot be pulled out any morebut rewinds after being pulled out fully.
(2) Check that the belt can be pulled out and rewound after the belt has been fully rewound.
If operation is not as specified, replace the belt assy.
17. INSTALL REAR SEAT BELT ASSY OUTER CENTER
(40/60 FOLDING TYPE REAR SEAT)
(a) Install the belt assy with the bolt on the retractor side. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
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B70206
LockUnlock
45

B66570
Protrusion Part
Front
Front
Mark
Protrusion Part
B70207Lock
Unlock
45

±
SEAT BELT REAR SEAT BELT (SEDAN MODELS)
61±17
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check the degree of tilt when the belt begins to lock the
ELR.
NOTICE:
Do not disassemble the retractor.
(1) Check that the belt does not lock within 15
of tilt in
all directions but locks with over 45
of tilt when
gently moving the retractor.
If operation is not as specified, replace the belt assy.
(c) Install the belt with the bolt on the floor anchor side. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
(d) Check the ELR lock.
NOTICE:
The check should be performed with the a ssembly
installed. (1) Check that the belt locks by pulling it out quickly af-ter installation.
HINT:
The seat belt does not lock when it is pulled out to a length of
955 mm (37.60 in.) or less.
If operation is not as specified, replace the belt assy.
(e) Check the fastening function of the child restraint system.
NOTICE:
The check should be performed with the a ssembly
installed. (1) Check that the belt cannot be pulled out any more
but rewinds after being pulled out fully.
(2) Check that the belt can be pulled out and rewound after the belt has been fully rewound.
If operation is not as specified, replace the belt assy.
18. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY
INNER
(a) Install the floor anchor and belt with the bolt as shown in the illustration.
Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
NOTICE:
Make sure that the anchor part does not run onto the protru-
sion part of the floor panel.
19. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER
(a) Install the belt with the bolt on the retractor side.
Torque:
7.5 N
m (76.5 kgf
cm, 66 in.
lbf) for front bolt
42 N
m (430 kgf
cm, 31 ft
lbf) for upper bolt
(b) Check the degree of tilt when the belt begins to lock the
ELR.
NOTICE:
Do not disassemble the retractor.
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B70206
LockUnlock
45

B66570
Protrusion Part
Front
Front
Mark
Protrusion Part
B66568Lock
Unlock
45

±
SEAT BELT REAR SEAT BELT (WAGON MODELS)
61±25
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check the degree of tilt when the belt begins to lock the
ELR.
NOTICE:
Do not disassemble the retractor.
(1) Check that the belt does not lock within 15
of tilt in
all directions but locks with over 45
of tilt when
gently moving the retractor.
If operation is not as specified, replace the belt assy.
(c) Install the belt with the bolt on the floor anchor side. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
(d) Check the ELR lock.
NOTICE:
The check should be performed with the a ssembly
installed. (1) Check that the belt locks by pulling it out quickly af-ter installation.
HINT:
The seat belt does not lock when it is pulled out to a length of
955 mm (37.60 in.) or less.
If operation is not as specified, replace the belt assy.
(e) Check the fastening function of the child restraint system.
NOTICE:
The check should be performed with the a ssembly
installed. (1) Check that the belt cannot be pulled out any more
but rewinds after being pulled out fully.
(2) Check that the belt can be pulled out and rewound after the belt has been fully rewound.
If operation is not as specified, replace the belt assy.
20. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY
INNER
(a) Install the floor anchor and belt with the bolt as shown in the illustration.
Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
NOTICE:
Make sure that the anchor part does not run onto the protru-
sion part of the floor panel.
21. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER
(a) Install the belt with the bolt on the retractor side.
Torque:
7.5 N
m (76.5 kgf
cm, 66 in.
lbf) for front bolt
42 N
m (430 kgf
cm, 31 ft
lbf) for upper bolt
(b) Check the degree of tilt when the belt begins to lock the
ELR.
NOTICE:
Do not disassemble the retractor.
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700TJ±01
B56435
Slide
B61414
Slide
B66957
Butyl TapeMirror Base
a
b
c
d
70±64
±
WINDSHIELD/WINDOWGLASS/MIRROR INNER REAR VIEW MIRROR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
INNER REAR VIEW MIRROR ASSY
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated. 1. REMOVE INNER REAR VIEW MIRROR ASSY(EC MIRROR)
(a) Remove the inner rear view mirror cover.
(b) Remove the rain sensor covers (See page XX±XXX).
(c) Remove the screw.
(d) Disconnect the connector.
(e) Remove the rear view inner mirror.
2. REMOVE INNER REAR VIEW MIRROR ASSY (NORMAL MIRROR)
(a) Remove the inner rear view mirror, as shown in the il- lustration.
3. INSTALL INNER REAR VIEW MIRROR ASSY (NORMAL MIRROR)
(a) Prepare 2 pieces of butyl tape having the dimensions, as
shown in the illustration.
(b) While extending them until they fit the length of the mirror base (24 mm, (0.944 in.)), apply them to both side of the
mirror base respectively.
(c) Install inner rear view mirror.
NOTICE:
If butyl tape spreads out of the inside groove when applied,
remove the excessive amount of tape so that it will not stick
to the glass. Dimension:
a10 mm (0.393 in.)
b4 mm (0.157 in.)
c6 mm (0.236 in.)
d24 mm (0.944 in.)
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