Steering column TOYOTA AVENSIS 2003 Service Repair Manual

NEW MODEL OUTLINEMO-28
EQUIPMENT LIST

: Standard OP: Option
EuropeGeneral
ENTRYMID
TECHNICALMID
ELEGANTGeneral
Countries
Exterior
Rear SpoilerWagon


Ð
Side Protection MouldingOPOPOPOP
WindshieldGreen


Ð
Front SideGreen




GlassRear Side & BackGreen



GlassRear Side & BackWagonPrivacyOPOPOPÐ
Rear QuarterWagonGreen


ÐRear QuarterWagonPrivacyOPOPOPÐ
Chassis
195/65 R153ZZ-FE & 1ZZ-FE & 1AZ-FE




205/55 R161AZ-FSE & 1CD-FTV


Ð
Tire205/55 R163ZZ-FE & 1ZZ-FE & 1AZ-FEOPOPOPOP
215/45 R171AZ-FEÐOPOPÐ215/45 R171AZ-FSEÐOPOPÐ
15 x 6J Steel3ZZ-FE & 1ZZ-FE & 1AZ-FE




16x61/2J Steel1AZ-FSE & 1CD-FTV


Ð16 x 6 1/2 J Steel3ZZ-FE & 1ZZ-FE & 1AZ-FEOPOPOPOP
Disc Wheel16 x 6 1 / 2 JJ AluminumOPOPOPOP
16 x 6 1 / 2 JJ Light Weight AluminumOPOPOPOP
17 x 7JJ Aluminum1AZ-FEÐOPOPÐ17 x 7JJ Aluminum1AZ-FSEÐOPOPÐ
ABS (Anti-lock Brake System) with EBD (Electronic Brake force Distrib\
ution)




VSC (Vehicle Stability Control) & Brake1AZ-FSEÐ

(y)Assist & TRC (Traction Control)1CD-FTVOPOPOPÐ
Wheel4-Spoke Urethane
ÐÐ
Wheel4-Spoke LeatherÐ

Ð
SteeringColumnManual Tilt & Telescopic



SteeringEPS*13ZZ-FE & 1ZZ-FE


Ð
Hydraulic Type Power
Steering1AZ-FSE & 1CD-FTV & 1AZ-FE




Body
CoverFabric



CoverLeather1AZ-FSE & 1CD-FTVÐOPOPÐ
FrontManual




SeatFrontPower1AZ-FSE & 1CD-FTVÐOPOPÐ
FixSedan
ÐÐÐ
Rear60:40 FoldingSedanÐ



60:40 Double FoldingLiftback & Wagon


Ð
SeatBelt
Front3-Point ELR*2 Electrical Sensing Type Pretensioner
& Force Limiter




BeltRear3-Point ELR*2 & ALR*3




CRS (Child Restraint System) Anchor System (Rear Outside Seat Only)




*1: Electoronic Power Steering
*2: Emergency Locking Retractor
*3: Automatic Locking Retractor
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D30401
Mark
01±10
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Even in the case of a minor collision where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly and seat belt pretensioner should be in\
spected
(See pages 60±19, 60±19 and 61±9).
(4)Never use the SRS related parts from another vehicle. When replacing the part\
s, replace them with new parts.
(5)Before repairs, remove the airbag sensor if there is a possibility of sh\
ock during repairs.
(6)Never disassemble and repair the center airbag sensor assembly, side airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly,
curtain shield airbag assembly or seat belt pretensioner.
(7)If the center airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly have been dropped, or if the\
re are cracks,
dents or other defects in the case, bracket or connector, replace them with new ones.
(8)Do not directly expose the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly or the seat belt pretensioner
to hot air or flames.
(9)Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting electrical cir-
cuits.
(10)Information labels are attached to the SRS components. Follow the instru\
ctions on the notices.
(11)After work on the supplemental restraint system is completed, check the SRS w\
arning light (See page 05±1184)
(b)SPIRAL CABLE (in Combination Switch)(1)The steering wheel must be fitted correctly to thesteering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
troubles may occur. Refer to page 60±26 of this
manual concerning the correct installation of the
steering wheel.
(c) HORN BUTTON ASSEMBLY (with Airbag) (1) When removing the horn button assembly or handling a new horn button, it sho\
uld be placed withthe top of the pad surface facing upward. Placing it with the pad surface facing downward may
lead to a serious accident if the airbag deploys for some reasons. Also, do \
not place anything
on top of the horn button.
(2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
(3) Grease should not be applied to the horn button assembly, and the pad should not be cleaned with any type of detergent.
(4) Store the horn button assembly where the ambient temperature remains below 93
C (200
F),
without high humidity and away from electrical noise.
(5) When using electric welding, disconnect the airbag connector (4 yellow pins\
) under the steering column near the combination switch connector before starting work.
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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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031FX±01
±
SERVICE SPECIFICATIONS STEERING COLUMN
03±57
AVENSIS REPAIR MANUAL (RM1018E)
STEERING COLUMN
SERVICE DATA
STEERING SYSTEM
Steering wheel freeplay Maximum30 mm (1.18 in.)
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031FZ±01
03±58
±
SERVICE SPECIFICATIONS STEERING COLUMN
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Steering intermediate shaft assy No. 2 x Oil pressure power steering
column assy (LHD steering positoin type)2828621
Steering sliding yoke sub±assy x Oil pressure power steering column a\
ssy
(RHD steering positoin type)2828621
Steering intermediate shaft assy No. 2 x Electric power steering column \
assy (LHD steering positoin type)3536026
Steering sliding yoke sub±assy x Electric power steering column assy
(RHD steering positoin type)3536026
Steering sliding yoke sub±assy x Steering intermediate shaft assy No.\
23536026
Steering column assy set bolt2121415
Steering sliding yoke sub±assy x Steering gear assy
(LHD steering positoin type)3536026
Steering intermediate shaft assy No. 2 x Steering gear assy
(RHD steering positoin type)3536026
Steering wheel set nut5051037
Steering wheel pad set screw (Torx screw)8.89078 in.´lbf
Steering column cover LWR x Steering column assy5.05144 in.´lbf
Instrument panel airbag assy1818413
Power steering ECU assy (Bolt A)88271 in.´lbf
Power steering ECU assy (Bolt B)15.515811
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031HM±01
±
SERVICE SPECIFICATIONS SUPPLEMENTAL RESTRAINT SYSTEM
03±63
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Horn button assy x Steering wheel assy8.89078 in.
lbf
Steering wheel assy x Steering column assy5051037
Instrument panel passenger airbag assy x Instrument panel reinforcement2020014
Curtain shield airbag assy x Body3.53631 in.
lbfCurtain shield airbag assy x Body3.5
14
36
143
31 in. lbf
10
Instrument panel airbag assy x Instrument panel reinforcement1818413
Airbag sensor assy center x Body17.517813
Airbag front sensor set bolt7.57666 in.
lbf
Side airbag sensor assy LH x Body17.517813
Airbag sensor rear LH x Body17.517813
Seat position airbag sensor x Front seat8.08271 in.
lbf
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A77313
Cooler Bracket
(LHD (w/ Air Conditioner) Steering Position Type)
Oil Reservoir
Bracket No. 1 Heater Outlet Water Hose
Heater Inlet Water Hose
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silercer Sheet
Front Stabilizer Link Assy
Front Axle Assy
35 (360, 26)
7.0 (71, 62 in.
lbf)
74 (755, 55 )
216 (2,203,159 )
142 (1,448,105 )
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part

Front Axle Hub Nut
Tie Rod End Sub±assy
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)

Cotter Pin
49 (500, 36)
Front Suspension Arm
Sub±assy Lower No. 1
14±114
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A79419
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
29 (296, 21)
80 (816, 59)
133 (1,348, 97)
43 (440, 32)
30 (302, 22)
43 (440, 32)

Gasket
74 (755, 55)
49 (500, 36)

Gasket


Cotter Pin
V (Cooler Compressor
to Crankshaft pulley)
Belt No. 1
Glove Compartment Door Assy
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silencer Sheet
Front Stabilizer Link Assy LHClip
Tie Rod End Sub±assy LH
Front Axle Hub LH Nut
Front Suspension Member
Brace Rear LH
Compression
Spring
Floor Panel Brace Front
Exhaust Pipe Assy Front
Compression Spring
w/ A/C:
Compressor And Magnetic Clutch
Front Drive Shaft Assy LH Clip
Transmission Control
Cable Assy
Clip
Clutch Accumulator Assy
Clutch Release Cylinder Assy
Transmission Control Cable Assy
35 (357, 26)
142 (1,448, 105)
Clip
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±279
AVENSIS REPAIR MANUAL (RM1018E)
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A79140
A79184
14±288
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
34.SEPARATE RETURN TUBE SUB±ASSY
(a)Remove the 2 clamp bolts and separate the return tube sub±assy.
35.SEPARATE VANE PUMP OIL RESERVOIR ASSY
36.REMOVE FRONT AXLE HUB LH NUT (See page 30±6) SST09930±00010
HINT:
Perform the same procedure as above on the opposite side.
37.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
HINT:
Perform the same procedure as above on the opposite side.
38.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
HINT:
Perform the same procedure as above on the opposite side.
39. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and the column hole cover silencer sheet.
40.REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
41.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 26±21)
HINT:
Perform the same procedure as above on the opposite side.
42.SEPARATE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side.
43. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Disconnect the height control sensor connector (w/ Dis-charge head lamp).
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A76704
Grove Compartment Door Assy
Cowl Side Trim Board RH
Front Door Scuff Plate RH
Clip
Clip
Column Hole Cover Silencer Sheet
Steering Intermediate Shaft

Cotter Pin
Tie Rod End Sub±assy LH
Front Suspension Arm
Sub±assy Lower No. 1 LH
Front Drive Shaft Assy LH
Front Stabilizer Link Assy LH
Exhaust Pipe Assy Front Floor Panel Brace FrontCompression
Spring
Compression Spring

Gasket

Gasket
89 (908, 66)
216 (2,203, 160)
49 (500, 36)
74 (755, 55)
35 (357, 26)
89 (908, 66)
Front Axle Hub LH Nut

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
43 (440, 32)
30 (306, 22)
43 (440, 32)
Front Floor Footrest (RHD)
Instrument Panel Under
Cover Sub±assy No. 2
14±22
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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