1999 TOYOTA AVENSIS Supplement

SR0WD–01
F03717
F03718
F03719
Vinyl Tape
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–9
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) Temporarily install the vane pump pulley set nut.
(c) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.3 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 union.
3. REMOVE PRESSURE PORT UNION
(a) Remove the pressure port union.
(b) Remove the O–ring from the union.
4. REMOVE FLOW CONTROL VALVE AND SPRING
5. REMOVE REAR HOUSING, WAVE WASHER AND SIDE
REAR PLATE
(a) Using 2 screwdrivers, remove the snap ring.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the vane pump shaft.
(c) Using a plastic hammer, tap out the rear housing, wave
washer and side rear plate.
(d) Remove the O–ring from the rear housing.
(e) Remove the O–ring from the side rear plate.
6. REMOVE CAM RING AND 10 VANE PLATES
NOTICE:
Be careful not to drop the plate.
7. REMOVE VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
8. REMOVE VANE PUMP ROTOR AND SIDE FRONT
PLATE
(a) Using a screwdriver, remove the snap ring from the vane
pump shaft.
(b) Remove the vane pump rotor and side front plate.
(c) Remove the 2 O–rings from the side front plate.
9. REMOVE SHORTER STRAIGHT PIN
Using pliers, remove the shorter straight pin from the side front
plate.

SR–10– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
10. REMOVE LONGER STRAIGHT PIN
Using pliers, remove the longer straight pin from the front hous-
ing.

F01876
Bushing
Front
Housing Vane Pump
Shaft
SR0WE–01
Z06061
Thickness
Height
Length
R10282
Feeler Gauge
F01319
Inscribed Mark
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–11
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.01 – 0.03 mm (0.0004 – 0.0012 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.1 mm (0.319 in.)
Minimum thickness: 1.797 mm (0.0708 in.)
Minimum length: 14.988 mm (0.5901 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with the one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None

F03747
F04785
Compressed Air
F01318
Inscribed Mark
SR–12– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
HINT:
There are 5 vane plate lengths with the following rotor and cam
ring marks:
Rotor and cam
ring markVane plate part
numberVane plate length
mm (in.)
None44345–1201014.996 – 14.998
(0.59039 – 0.59047)
144345–1202014.994 – 14.996
(0.59032 – 0.59039)
244345–1203014.992 – 14.994
(0.59024 – 0.59032)
344345–1204014.990 – 14.992
(0.59016 – 0.59024)
444345–1205014.988 – 14.990
(0.59008 – 0.59016)
3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it
falls smoothly into the valve hole by its own weight.
(b) Check the flow control valve for leakage. Close one of the
holes and apply compressed air 392 – 490 kPa (4 – 5
kgf/cm
2, 57 – 71 psi) into the opposite side hole, and con-
firm that air does not come out from the end hole.
If necessary, replace the valve with the one having the same let-
ter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

R08702
F01345
Vinyl Tape
F01317
Press
Oil Seal SST
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–13
4. INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 36.0 mm (1.417 in.)
If it is not within the specification, replace the spring.
5. 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 front housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST and a press, press in the oil seal.
SST 09950–60010 (09951–00310),
09950–70010 (09951–07100)
NOTICE:
Make sure to install the oil seal facing the correct direction.

SR0WF–01
Z13635
Inscribed Mark
F03721
Longer
Straight Pin
Hole
F01314
Inscribed Mark
SR–14– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID (See page SR–6)
2. INSTALL LONGER STRAIGHT PIN
Using a plastic hammer, tap in a new longer straight pin to the
front housing.
NOTICE:
Be careful not to damage the pin.
3. INSTALL SHORTER STRAIGHT PIN
Install a new short straight pin to the side front plate.
NOTICE:
Be careful not to damage the pin.
4. INSTALL SIDE FRONT PLATE AND VANE PUMP RO-
TOR
(a) Coat 2 new O–rings with power steering fluid and install
them to the side front plate.
(b) Install the plate to the pump shaft.
NOTICE:
Make sure to install the plate facing the correct direction.
(c) Install the vane pump rotor to the pump shaft with the in-
scribed mark facing outward.
(d) Install a new snap ring to the vane pump shaft.
5. INSTALL VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
Align the hole of the side front plate and longer straight pin, and
tap in the shaft with a plastic hammer.
NOTICE:
Be careful not to damage the oil seal and O–rings.
6. INSTALL CAM RING
Align the holes of the cam ring and 2 straight pins and install the
ring with the inscribed mark facing outward.

F01315
Round End
F01316
F03722
Press
– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)SR–15
7. INSTALL VANE PLATES
Install the 10 plates with the round end facing outward.
8. INSTALL SIDE REAR PLATE
(a) Coat a new O–ring with power steering fluid and install it
to the side rear plate.
(b) Align the holes of the plate and 2 straight pins, and install
the plate.
9. INSTALL WAVE WASHER
Install the washer so that its protrusions fit into the slots in the
side rear plate.
10. INSTALL REAR HOUSING
(a) Coat a new O–ring with power steering fluid and install it
to the rear housing.
(b) Install the housing and use a press to push down on the
wave washer hard enough to compress it.
NOTICE:

Do not apply too much pressure.

Be careful not to damage the O–ring.
(c) Install a new snap ring.
11. INSTALL SPRING AND FLOW CONTROL VALVE
Install the valve facing the correct direction
(See page SR–6).
12. INSTALL PRESSURE PORT UNION
(a) Coat a new O–ring with power steering fluid and install it
to the pressure pore union.
(b) Install the union.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
13. 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 bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
14. MEASURE PS VANE PUMP ROTATING TORQUE
(See page SR–9)

SR0WG–01
F04155
SST
F08958
SR–16– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
INSTALLATION
1. INSTALL PULLEY COVER
Install the pulley cover to the PS vane pump with the bolt.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
2. INSTALL PS VANE PUMP ASSEMBLY
Install the PS vane pump to the pulley bracket and engine with
the 3 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
3. CONNECT PRESSURE FEED TUBE
Place a new gasket to the pressure feed tube and connect them
with the union bolt.
Torque: 52 N·m (525 kgf·cm, 38 ft·lbf)
4. CONNECT RETURN HOSE
Connect the return hose with the clip.
5. INSTALL VANE PUMP PULLEY
(a) Install the woodruff key to the vane pump shaft.
(b) Install the vane pump pulley.
(c) Using SST to stop the pulley rotating, torque the nut.
SST 09960–10010 (09962–01000, 09963–01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
6. INSTALL DRIVE BELT
(a) Install the drive belt to the pulley.
(b) Adjust drive belt tension with the belt tension adjusting
bolt (See page SR–1).
(c) Torque the idler pulley set nut.
Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)
7. BLEED POWER STEERING SYSTEM
(See Pub. No. RM599E on page SR–5)