Get STEERING Guide for Toyota Avensis 4 Door First Generation (1997-2003)

STEERING

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR–1

SR–2

SR–6

POWER STEERING FLUID . . . . . . . . . . . . . . .

TILT STEERING COLUMN . . . . . . . . . . . . . . . .

POWER STEERING VANE PUMP

(1ZZ–FE, 3ZZ–FE) . . . . . . . . . . . . . . . . . . . . .

POWER STEERING VANE PUMP

SR–8

(1AZ–FSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SR–19

REFER TO FOLLOWING REPAIR MANUALS:

ManualName

Pub. No.

RM599E

AVENSIS/CORONA Chassis and Body Repair Manual

Supplement(Aug.,1999)

RM698E

NOTE: The above pages contain only the points which differ

from the above listed manuals.

SR–1

STEERING

–

DRIVE BELT

SR08H–06

INSPECTION

INSPECT DRIVE BELT

Visually check the drive belt for excessive wear, frayed cords,

etc.

If any defect has been found, replace the drive belt.

HINT:

S

Cracks on the rib side of a belt are considered acceptable.

If the missing chunks from the ribs are found on the drive

belt, it should be replaced.

P06717

S

After installing a drive belt, check that it fits properly in the

ribbed grooves.

Check with your hand to confirm that the drive belt has not

slipped out of the groove on the bottom of the pulley.

CORRECT

WRONG

F01336

AVENSIS/CORONA SUP (RM781E)

SR–2

STEERING

–

POWER STEERING FLUID

SR08I–07

BLEEDING

1.

2.

CHECK FLUID LEVEL (See page SR–3)

JACK UP FRONT OF VEHICLE AND SUPPORT IT

WITH STANDS

3.

TURN STEERING WHEEL

With the engine stopped, turn the steering wheel slowly from

lock to lock several times.

4.

5.

LOWER VEHICLE

START ENGINE

Run the engine at idle for a few minutes.

6. TURN STEERING WHEEL

(a) With the engine idling, turn the steering wheel to left or

right full lock position and keep it there for 2–3 seconds,

then turn the steering wheel to the opposite full lock posi-

tion and keep it there for 2–3 seconds.

(b) Repeat (a) several times.

7.

STOP ENGINE

8.

CHECK FOR FOAMING OR EMULSIFICATION

Normal

Abnormal

If the system has to be bled twice specifically because of foam-

ing or emulsification, check for fluid leaks in the system.

9.

CHECK FLUID LEVEL (See page SR–3)

R11741

AVENSIS/CORONA SUP (RM781E)

SR–3

STEERING

–

POWER STEERING FLUID

SR08J–05

INSPECTION

1.

CHECK FLUID LEVEL

(a) Keep the vehicle level.

(b) With the engine stopped, check the fluid level in the oil

reservoir.

HOT

COLD

If necessary, add fluid.

Fluid: ATF DEXRON® II or III

HINT:

R11740

Check that the fluid level is within the HOT LEVEL range on the

reservoir. If the fluid is cold, check that it is within the COLD

LEVEL range.

(c) Start the engine and run it at idle.

(d) Turn the steering wheel from lock to lock several times to

boost fluid temperature.

Fluid temperature: 80°C (176°F)

(e) Check for foaming or emulsification.

If there is foaming or emulsification, bleed power steering sys-

tem (See page SR–2).

Normal

Abnormal

R11741

(f)

With the engine idling, measure the fluid level in the oil

reservoir.

5 mm (0.20 in.) or less

(g) Stop the engine.

(h) Wait a few minutes and remeasure the fluid level in the oil

reservoir.

Maximum fluid level rise: 5 mm (0.20 in.)

If a problem is found, bleed power steering system (See page

SR–2).

Engine Idling

EngineStopped

R11786

(i)

Check the fluid level.

AVENSIS/CORONA SUP (RM781E)

SR–4

STEERING

–

POWER STEERING FLUID

2.

CHECK STEERING FLUID PRESSURE

(a) Disconnect the pressure feed tube from the PS vane

pump.

(1ZZ–FE, 3ZZ–FE Engines: See page SR–10)

(1AZ–FSE Engine: See page SR–21)

(b) Connect SST, as shown in the illustration below.

SST 09640–10010 (09641–01010, 09641–01030,

09641–01060)

NOTICE:

Check that the valve of the SST is in the open position.

1ZZ–FE, 3ZZ–FE Engines:

Attachment

1AZ–FSE Engine:

SST

Pressure Feed Tube

SST

OUT

Attachment

IN

OUT

Pressure

Feed Tube

PS Vane Pump

Attachment

PS Vane Pump

Attachment

F13065

(c) Bleed the power steering system (See page SR–2).

(d) Start the engine and run it at idle.

(e) Turn the steering wheel from lock to lock several times to

boost fluid temperature.

Fluid temperature: 80 °C (176 °F)

AVENSIS/CORONA SUP (RM781E)

SR–5

STEERING

–

POWER STEERING FLUID

(f)

With the engine idling, close the valve of the SST and ob-

serve the reading on the SST.

Minimum fluid pressure:

Oil

reservoir

1ZZ–FE, 3ZZ–FE Engines:

8,300 kPa (85 kgf/cm², 1209 psi)

1AZ–FSE Engine:

PS Gear

Closed

8,800 kPa (90 kgf/cm², 1280 psi)

PS Vane

Pump

NOTICE:

SST

S

Do not keep the valve closed for more than 10 se-

conds.

Z15498

S

Do not let the fluid temperature become too high.

(g) With the engine idling, open the valve fully.

(h) Measure the fluid pressure at engine speeds of 1,000 rpm

and 3,000 rpm.

Oil

reservoir

Difference fluid pressure:

490 kPa (5 kgf/cm², 71 psi) or less

NOTICE:

PS Gear

Open

Do not turn the steering wheel.

PS Vane

Pump

SST

Z15499

(i)

With the engine idling and valve fully opened, turn the

steering wheel to full lock.

Oil

reservoir

Minimum fluid pressure:

1ZZ–FE, 3ZZ–FE Engines:

Lock Position

Open

8,300 kPa (85 kgf/cm², 1209 psi)

1AZ–FSE Engine:

PS Gear

8,800 kPa (90 kgf/cm², 1280 psi)

NOTICE:

PS Vane

Pump

SST

S

Do not maintain lock position for more than 10 se-

conds.

Z15500

S

Do not let the fluid temperature become too high.

Disconnect the SST.

(j)

SST 09640–10010 (09641–01010, 09641–01030,

09641–01060)

(k) Connect the pressure feed tube to the PS vane pump.

(1ZZ–FE, 3ZZ–FE Engines: See page SR–18)

(1AZ–FSE Engine: See page SR–29)

(l)

Bleed the power steering system (See page SR–2).

AVENSIS/CORONA SUP (RM781E)

SR–6

STEERING

–

TILT STEERING COLUMN

SR0IB–02

COMPONENTS

HINT:

If the steering column assembly (w/ VSC) is removed or replaced, calibrate the steering angle sensor zero

point (See page DI–171).

Instrument Cluster FinishPanel

Steering WheelPad

50 (510, 37)

Column Upper Cover

Torx Screw

8.8(90, 78 in.·lbf)

Steering Wheel

Torx Screw

8.8(90, 78 in.·lbf)

Combination Switch

(w/ Spiral Cable)

25.5(260,19)

Column Lower Cover

35 (360, 26)

25.5 (260, 19)

Steering Column Assembly

Clamp

Lower Instrument Finish Panel

w/ VSC:

Steering Column Assembly

Hood Lock Control Cable

N·m (kgf·cm, ft·lbf) : Specified torque

F13066

AVENSIS/CORONA SUP (RM781E)

SR–7

STEERING

–

TILT STEERING COLUMN

w/ Engine ImmobiliserSystem:

w/ Shift LockSystem:

Transponder Key

Computer Assembly

Key Inter Lock Solenoid

Transponder Key

Computer Case

KeyCylinder

Column Upper Bracket

Key Unlock

Warning Switch

Column Upper Clamp

Ignition Switch

z Tapered–headBolt

w/ VSC:

Steering Column Assembly

z Non–reusable part

F13067

AVENSIS/CORONA SUP (RM781E)

SR–8

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE)

SR0YO–05

COMPONENTS

Pressure Feed Tube

7.8 (80, 69 in.·lbf)

44 (450, 33)

*37 (375, 27)

Oil Pressure Switch Connector

Suction Hose

PS Vane Pump Assembly

Clip

37 (370, 27)

Drive Belt

Engine Under Cover RH

x 5

: Specified torque

N·m (kgf·cm, ft·lbf)

* For use with SST

F13062

AVENSIS/CORONA SUP (RM781E)

SR–9

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

Pressure PortUnion

69 (700, 51)

z O–Ring

Flow Control Valve

Oil Pressure Switch

21 (210, 15)

Spring

Suction Port Union

z O–Ring

12 (120, 9)

44 (440, 32)

Heat Insulator

Front Housing

Pump Rear Bracket

z Oil Seal

22 (220, 16)

RearHousing

Vane Pump Shaft with

Vane Pump Pulley

22 (220, 16)

z Snap Ring

VanePump Rotor

SidePlate

z O–Ring

x 10

Vane Plate

22 (220, 16)

CamRing

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

Power steering fluid

F13063

AVENSIS/CORONA SUP (RM781E)

SR–10

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

SR0YP–02

REMOVAL

1.

REMOVE ENGINE UNDER COVER RH

Remove the 5 bolts and engine under cover RH.

2.

REMOVE DRIVE BELT

Loosen the drive belt tension by turning the drive belt tensioner

arm clockwise, and remove the drive belt.

Drive Belt

Tensioner Arm

F08868

3.

DISCONNECT SUCTION HOSE

Remove the clip and disconnect the suction hose.

NOTICE:

Take care not to spill fluid on the drive belt.

4.

DISCONNECT PRESSURE FEED TUBE

SST

(a) Using SST, disconnect the pressure feed tube.

SST 09023–12700

(b) Remove the bolt and disconnect the pressure feed tube

clamp.

F13068

5.

6.

DISCONNECT OIL PRESSURE SWITCH CONNECTOR

REMOVE PS VANE PUMP ASSEMBLY

Remove the 2 pump assembly set bolts, nuts and PS vane

pump assembly.

AVENSIS/CORONA SUP (RM781E)

SR–11

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

SR0VS–07

DISASSEMBLY

NOTICE:

When using a vise, do not overtighten it.

1.

MEASURE PS VANE PUMP ROTATING TORQUE

(a) Check that the pump rotates smoothly without abnormal

noise.

(b) Using a torque wrench, check the pump rotating torque.

Rotating torque:

F13466

0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less

2.

REMOVE SUCTION PORT UNION

(a) Remove the bolt and suction port union.

(b) Remove the O–ring from the suction port union.

3.

REMOVE PRESSURE PORT UNION, FLOW CONTROL

VALVE AND SPRING

(a) Remove the pressure port union, flow control valve and

spring.

(b) Remove the O–ring from the pressure port union.

4.

REMOVE OIL PRESSURE SWITCH

NOTICE:

Be careful not to drop the oil pressure switch.

If the oil pressure switch is dropped or strongly damaged, re-

place it with a new one.

5.

REMOVE REAR HOUSING

(a) Remove the bolt, nut, heat insulator and pump rear brack-

et.

(b) Remove the 4 bolts and rear housing.

(c) Remove the O–ring from the rear housing.

6.

REMOVE CAM RING, 10 VANE PLATES, VANE PUMP

ROTOR AND SIDE PLATE

(a) Remove the cam ring and 10 vane plates.

NOTICE:

Take care not to drop the vane plate.

(b) Using a screwdriver, remove the snap ring, vane pumpro-

tor and side plate.

(c) Remove the 2 O–rings from the side plate.

7.

REMOVE VANE PUMP SHAFT WITH VANE PUMP

PULLEY

AVENSIS/CORONA SUP (RM781E)

SR–12

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

SR0VT–07

INSPECTION

1.

MEASURE OIL CLEARANCE BETWEEN VANE PUMP

SHAFT AND BUSHING

Bushing

Using a micrometer and a caliper gauge, measure the oil clear-

ance.

Standard clearance:

0.021 – 0.043 mm (0.0008 – 0.0017 in.)

Maximum clearance: 0.07 mm (0.0028 in.)

If it is more than the maximum, replace the front housing and

vane pump shaft.

Front Housing

Vane Pump Shaft

F09875

2.

INSPECT VANE PUMP ROTOR AND VANE PLATES

Thickness

(a) Using a micrometer, measure the height, thickness and

length of the 10 vane plates.

Height

Minimum height: 7.6 mm (0.299 in.)

Minimum thickness: 1.405 mm (0.0553 in.)

Minimum length: 11.993 mm (0.4722 in.)

Length

N00372

(b) Using a feeler gauge, measure the clearance between

the vane pump rotor groove and vane plate.

Maximum clearance: 0.03 mm (0.0012 in.)

Feeler Gauge

R10282

AVENSIS/CORONA SUP (RM781E)

SR–13

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

If it is more than the maximum, replace the vane plate and/or

vane pump rotor with the one having the same mark stamped

on the cam ring.

Inscribed mark: 0, 1, 2, 3, or 4

HINT:

There are 5 vane plate lengths corresponding to the following

vane pump rotor and cam ring marks:

Vane pump rotor and

cam ring mark

Vane plate part

number

Vane plate length

mm (in.)

Inscribed Mark

F08475

12.001 – 12.003

0

1

2

3

4

44345 – 02110

44345 – 02120

44345 – 02130

44345 – 02140

44345 – 02150

(0.47248–0.47256)

11.999 – 12.001

(0.47240–0.47248)

11.997 – 11.999

(0.47232–0.47240)

11.995 – 11.997

(0.47224–0.47232)

11.993 – 11.995

(0.47216–0.47224)

3.

INSPECT FLOW CONTROL VALVE

(a) Coat the flow control valve with power steering fluid and

check that it falls smoothly into the valve hole of the front

housing by its own weight.

F08476

(b) Check the flow control valve for leakage. Close one of the

holes and apply compressed air of 392 – 490 kPa (4 – 5

kgf/cm², 57 – 71 psi) into the opposite side hole, and con-

firm that air does not come out from the end hole.

Compressed Air

F08804

If necessary, replace the flow control valve with the one having

the same letter as inscribed on the front housing.

Inscribed mark: A, B, C, D, E or F

Inscribed Mark

F08478

AVENSIS/CORONA SUP (RM781E)

SR–14

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

4.

INSPECT SPRING

Using vernier calipers, measure the free length of the spring.

Minimum free length: 35.8 mm (1.409 in.)

If it is not within the specification, replace the spring.

Vernier Calipers

R08702

AVENSIS/CORONA SUP (RM781E)

SR–15

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

SR0VU–07

REPLACEMENT

Vinyl Tape

NOTICE:

When using a vise, do not overtighten it.

IF NECESSARY, REPLACE OIL SEAL

(a) Using a screwdriver with vinyl tape wound around its tip,

remove the oil seal.

NOTICE:

Be careful not to damage the bushing of the front housing.

F08479

(b) Coat a new oil seal lip with power steering fluid.

(c) Using SST, press in the oil seal.

SST 09950–60010 (09951–00280),

09950–70010 (09951–07100)

SST

NOTICE:

Make sure that the oil seal is installed facing in the correct

direction.

Oil Seal

F08480

AVENSIS/CORONA SUP (RM781E)

SR–16

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

SR0VV–07

REASSEMBLY

NOTICE:

When using a vise, do not overtighten it.

1.

2.

COAT PARTS INDICATED BY ARROWS WITH POWER

STEERING FLUID (See page SR–8)

INSTALL VANE PUMP SHAFT WITH VANE PUMP

PULLEY

3.

INSTALL SIDE PLATE

(a) Coat 2 new O–rings with power steering fluid, and install

them to the side plate.

(b) Align the dent of the side plate with the dent of the front

housing, and install the side plate.

NOTICE:

Make sure that the side plate is installed facing in the cor-

rect direction.

F08482

4.

INSTALL CAM RING

Inscribed Mark

Align the dent of the cam ring with the dent of the side plate, and

install the cam ring with the inscribed mark facing outward.

F08483

5.

INSTALL VANE PUMP ROTOR

Inscribed Mark

(a) Install the vane pump rotor with the inscribed mark facing

outward.

Round End

(b) Install a new snap ring to the vane pump shaft.

6.

INSTALL 10 VANE PLATES

Install the 10 vane plates with the round end facing outward.

F08484

7.

INSTALL REAR HOUSING

(a) Coat a new O–ring with power steering fluid, and install

it to the rear housing.

(b) Align the straight pin of the rear housing with the dents of

the cam ring, side plate and front housing, and install the

rear housing with the 4 bolts.

Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)

(c) Install the rear bracket and heat insulator with the bolt and

nut.

Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

SR–17

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

8.

9.

INSTALL OIL PRESSURE SWITCH

Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

INSTALL SPRING, FLOW CONTROL VALVE AND

PRESSURE PORT UNION

(a) Install the spring.

(b) Install the flow control valve facing in the correct direction

(See page SR–8).

(c) Coat a new O–ring with power steering fluid, and install

it to the pressure port union.

(d) Install the pressure port union.

Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)

10. INSTALL SUCTION PORT UNION

(a) Coat a new O–ring with power steering fluid, and install

it to the suction port union.

(b) Install the suction port union with the bolt.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

11. MEASURE PS VANE PUMP ROTATING TORQUE (See

page SR–11)

AVENSIS/CORONA SUP (RM781E)

SR–18

STEERING

–

POWER STEERING VANE PUMP(1ZZ–FE, 3ZZ–FE)

SR0YQ–02

INSTALLATION

1.

INSTALL PS VANE PUMP ASSEMBLY

Install the PS vane pump assembly with the 2 pump assembly

set bolts and nuts.

Torque: 37 N·m (370 kgf·cm, 27 ft·lbf)

2.

CONNECT OIL PRESSURE SWITCH CONNECTOR

NOTICE:

Be careful to prevent oil from being attached to the connec-

tor.

3.

CONNECT PRESSURE FEED TUBE

(a) Connect the pressure feed tube clamp with the bolt.

Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

(b) Using SST, connect the pressure feed tube.

SST 09023–12700

SST

Fulcrum

Length

Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)

HINT:

S

Use a torque wrench with a fulcrum length of 345 mm

(11.81 in).

F13069

S

This torque value is effective in case that SST is parallel

to a torque wrench.

4.

CONNECT SUCTION HOSE

Connect the suction hose with the clip.

5.

INSTALL DRIVE BELT

Loosen the drive belt tension by turning the drive belt tensioner

arm clockwise, and install the drive belt.

Drive Belt

Tensioner Arm

F08868

6.

INSTALL ENGINE UNDER COVER RH

Install the engine under cover RH with 5 bolts.

7.

BLEED POWER STEERING SYSTEM

(See page SR–2)

AVENSIS/CORONA SUP (RM781E)

SR–19

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

POWER STEERING VANE PUMP (1AZ–FSE)

SR19E–02

COMPONENTS

Union Bolt

52 (530, 38)

Oil Pressure Switch

z Gasket

Suction Hose

Pressure Feed Tube

Clip

PS Vane Pump Assembly

50(510,37)

Drive Belt

Engine Under Cover RH

x 5

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

* For use with SST

F13064

AVENSIS/CORONA SUP (RM781E)

SR–20

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

Pressure Port Union

69 (700, 51)

z O–Ring

Flow Control Valve

Oil Pressure Switch

21 (210, 15)

Spring

z O–Ring

SuctionPortUnion

12 (120, 9)

Vane Pump Shaft with

Vane Pump Pulley

Front Housing

z Oil Seal

22 (220, 16)

RearHousing

z Snap Ring

Vane Pump Rotor

Side Plate

z O–Ring

X10

Vane Plate

Cam Ring

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

Power steering fluid

F13606

AVENSIS/CORONA SUP (RM781E)

SR–21

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

SR1C8–01

REMOVAL

1.

REMOVE ENGINE UNDER COVER RH

Remove the 5 bolts and engine under cover RH.

2.

REMOVE DRIVE BELT

Using SST, loosen the drive belt tension by turning the drive belt

tensioner arm clockwise, and remove the drive belt.

SST 09249–63010

SST

F13071

3.

DISCONNECT SUCTION HOSE

Remove the clip and disconnect the suction hose.

NOTICE:

Take care not to spill fluid on the drive belt.

4.

REMOVE PRESSURE FEED TUBE

Remove the union bolt, gasket and pressure feed tube.

5.

REMOVE PS VANE PUMP ASSEMBLY

Loosen the 2 bolts and PS vane pump assembly.

F13070

AVENSIS/CORONA SUP (RM781E)

SR–22

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

SR0VS–08

DISASSEMBLY

NOTICE:

When using a vise, do not overtighten it.

1.

MEASURE PS VANE PUMP ROTATING TORQUE

(a) Check that the pump rotates smoothly without abnormal

noise.

(b) Using a torque wrench, check the pump rotating torque.

Rotating torque:

F11943

0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less

2.

REMOVE SUCTION PORT UNION

(a) Remove the bolt and suction port union.

(b) Remove the O–ring from the suction port union.

3.

REMOVE PRESSURE PORT UNION, FLOW CONTROL

VALVE AND SPRING

(a) Remove the pressure port union, flow control valve and

spring.

(b) Remove the O–ring from the pressure port union.

4.

REMOVE OIL PRESSURE SWITCH

NOTICE:

Be careful not to drop the oil pressure switch.

If the oil pressure switch is dropped or strongly damaged, re-

place it with a new one.

5.

REMOVE REAR HOUSING

(a) Remove the 4 bolts and rear housing.

(b) Remove the O–ring from the rear housing.

6.

REMOVE CAM RING, 10 VANE PLATES, VANE PUMP

ROTOR AND SIDE PLATE

(a) Remove the cam ring and 10 vane plates.

NOTICE:

Take care not to drop the vane plate.

(b) Using a screwdriver, remove the snap ring, vane pumpro-

tor and side plate.

(c) Remove the 2 O–rings from the side plate.

7.

REMOVE VANE PUMP SHAFT WITH VANE PUMP

PULLEY

AVENSIS/CORONA SUP (RM781E)

SR–23

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

SR0VT–08

INSPECTION

1.

MEASURE OIL CLEARANCE BETWEEN VANE PUMP

SHAFT AND BUSHING

Bushing

Using a micrometer and a caliper gauge, measure the oil clear-

ance.

Standard clearance:

0.021 – 0.043 mm (0.0008 – 0.0017 in.)

Maximum clearance: 0.07 mm (0.0028 in.)

If it is more than the maximum, replace the front housing and

vane pump shaft.

Front Housing

Vane Pump Shaft

F09875

2.

INSPECT VANE PUMP ROTOR AND VANE PLATES

Thickness

(a) Using a micrometer, measure the height, thickness and

length of the 10 vane plates.

Height

Minimum height: 7.6 mm (0.299 in.)

Minimum thickness: 1.405 mm (0.0553 in.)

Minimum length: 11.993 mm (0.4722 in.)

Length

N00372

(b) Using a feeler gauge, measure the clearance between

the vane pump rotor groove and vane plate.

Maximum clearance: 0.03 mm (0.0012 in.)

Feeler Gauge

R10282

AVENSIS/CORONA SUP (RM781E)

SR–24

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

If it is more than the maximum, replace the vane plate and/or

vane pump rotor with the one having the same mark stamped

on the cam ring.

Inscribed mark: 0, 1, 2, 3, or 4

HINT:

There are 5 vane plate lengths corresponding to the following

vane pump rotor and cam ring marks:

Vane pump rotor and

cam ring mark

Vane plate part

number

Vane plate length

mm (in.)

Inscribed Mark

F08475

12.001 – 12.003

0

1

2

3

4

44345 – 02110

44345 – 02120

44345 – 02130

44345 – 02140

44345 – 02150

(0.47248–0.47256)

11.999 – 12.001

(0.47240–0.47248)

11.997 – 11.999

(0.47232–0.47240)

11.995 – 11.997

(0.47224–0.47232)

11.993 – 11.995

(0.47216–0.47224)

3.

INSPECT FLOW CONTROL VALVE

(a) Coat the flow control valve with power steering fluid and

check that it falls smoothly into the valve hole of the front

housing by its own weight.

F08476

(b) Check the flow control valve for leakage. Close one of the

holes and apply compressed air of 392 – 490 kPa (4 – 5

kgf/cm², 57 – 71 psi) into the opposite side hole, and con-

firm that air does not come out from the end hole.

Compressed Air

F08804

If necessary, replace the flow control valve with the one having

the same letter as inscribed on the front housing.

Inscribed mark: A, B, C, D, E or F

Inscribed Mark

F08478

AVENSIS/CORONA SUP (RM781E)

SR–25

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

4.

INSPECT SPRING

Using vernier calipers, measure the free length of the spring.

Minimum free length: 35.8 mm (1.409 in.)

If it is not within the specification, replace the spring.

Vernier Calipers

R08702

AVENSIS/CORONA SUP (RM781E)

SR–26

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

SR0VU–08

REPLACEMENT

Vinyl Tape

NOTICE:

When using a vise, do not overtighten it.

IF NECESSARY, REPLACE OIL SEAL

(a) Using a screwdriver with vinyl tape wound around its tip,

remove the oil seal.

NOTICE:

Be careful not to damage the bushing of the front housing.

F08479

(b) Coat a new oil seal lip with power steering fluid.

(c) Using SST, press in the oil seal.

SST 09950–60010 (09951–00280),

09950–70010 (09951–07100)

SST

NOTICE:

Make sure that the oil seal is installed facing in the correct

direction.

Oil Seal

F08480

AVENSIS/CORONA SUP (RM781E)

SR–27

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

SR0VV–08

REASSEMBLY

NOTICE:

When using a vise, do not overtighten it.

1.

2.

COAT PARTS INDICATED BY ARROWS WITH POWER

STEERING FLUID (See page SR–19)

INSTALL VANE PUMP SHAFT WITH VANE PUMP

PULLEY

3.

INSTALL SIDE PLATE

(a) Coat 2 new O–rings with power steering fluid, and install

them to the side plate.

(b) Align the dent of the side plate with the dent of the front

housing, and install the side plate.

NOTICE:

Make sure that the side plate is installed facing in the cor-

rect direction.

F08482

4.

INSTALL CAM RING

Inscribed Mark

Align the dent of the cam ring with the dent of the side plate, and

install the cam ring with the inscribed mark facing outward.

F08483

5.

INSTALL VANE PUMP ROTOR

Inscribed Mark

(a) Install the vane pump rotor with the inscribed mark facing

outward.

Round End

(b) Install a new snap ring to the vane pump shaft.

6.

INSTALL 10 VANE PLATES

Install the 10 vane plates with the round end facing outward.

F08484

7.

INSTALL REAR HOUSING

(a) Coat a new O–ring with power steering fluid, and install

it to the rear housing.

(b) Align the straight pin of the rear housing with the dents of

the cam ring, side plate and front housing, and install the

rear housing with the 4 bolts.

Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)

8.

INSTALL OIL PRESSURE SWITCH

Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

SR–28

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

9.

INSTALL SPRING, FLOW CONTROL VALVE AND

PRESSURE PORT UNION

(a) Install the spring.

(b) Install the flow control valve facing in the correct direction

(See page SR–19).

(c) Coat a new O–ring with power steering fluid, and install

it to the pressure port union.

(d) Install the pressure port union.

Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)

10. INSTALL SUCTION PORT UNION

(a) Coat a new O–ring with power steering fluid, and install

it to the suction port union.

(b) Install the suction port union with the bolt.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

11. MEASURE PS VANE PUMP ROTATING TORQUE

(See page SR–22)

AVENSIS/CORONA SUP (RM781E)

SR–29

STEERING

–

POWER STEERING VANE PUMP(1AZ–FSE)

SR1C9–01

INSTALLATION

1.

INSTALL PS VANE PUMP ASSEMBLY

(a) Insert the 2 bolts to the PS vane pump assembly.

(b) Install the PS vane pump assembly.

(c) Tighten the 2 bolts.

Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)

F13070

2.

INSTALL PRESSURE FEED TUBE

Install the pressure feed tube and gasket to the PS vane pump

assembly with union bolt.

Torque: 52 N·m ( 530 kgf·cm, 38 ft·lbf)

3.

CONNECT SUCTION HOSE

Connect the suction hose with the clip.

4.

INSTALL DRIVE BELT

Using SST, loosen the drive belt tension by turning the drive belt

tensioner arm clockwise, and install the drive belt.

SST 09249–63010

SST

F13071

5.

INSTALL ENGINE UNDER COVER RH

Install the engine under cover RH with 5 bolts.

6.

BLEED POWER STEERING SYSTEM

(See page SR–2)

AVENSIS/CORONA SUP (RM781E)

STEERING for Your Toyota Avensis 4 Door First Generation (1997-2003)

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