1999 TOYOTA AVENSIS power steering

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)

Z14034
Fig.1
Fig.2Power Source
Safing
Sensor
Squibs
Deceleration Sensor
H01581
Outer
H01582
Lock of connector is released
Disconnection is completed
RS–6
– SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
(b) When the vehicle is involved in a frontal collision in the
hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. A
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensor. As illustrated in Fig. 2,
ignition is caused when current flows to the squib, which
happens when a safing sensor and the deceleration sen-
sor go on simultaneously. When a deceleration force acts
on the sensors, 2 squibs in the driver airbag and front pas-
senger airbag ignite and generate gas. The gas discharg-
ing into the driver airbag and front passenger airbag rap-
idly increases the pressure inside the bags, breaking
open the steering wheel pad and instrument panel door.
Bag inflation then ends, and the bags deflate as the gas
is discharged through discharge holes at the bag’s rear or
side.
7. DISCONNECTION OF SIDE AND CURTAIN SHIELD
AIRBAG SENSOR CONNECTOR
(a) With holding both flank sides of the outer, slide the outer
to the direction shown by an arrow.
(b) Lock of the connectors is released, then disconnect the
connectors.
HINT:
Make sure to hold both flank sides of the outer. If holding the top
and bottom sides, it will obstruct disconnection.

ID–2ALPHABETICAL INDEX (A – S)
A
Page
ABBREVIATIONS USED IN THIS MANUAL
(TERMS) IN–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING (PREPARATION) PP–22. . . . . . . . . . . . .
AIR CONDITIONING
(SERVICE SPECIFICATIONS) SS–19. . . . . . . . . . . . . . . . . .
B
BODY (PREPARATION) PP–20. . . . . . . . . . . . . . . . . . . . . . . . . .
BODY (SERVICE SPECIFICATIONS) SS–18. . . . . . . . . . . . . . .
BODY ELECTRICAL (PREPARATION) PP–19. . . . . . . . . . . . . .
BODY ELECTRICAL
(SERVICE SPECIFICATIONS) SS–16. . . . . . . . . . . . . . . . . .
BRAKE (PREPARATION) PP–11. . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE (SERVICE SPECIFICATIONS) SS–11. . . . . . . . . . . . . .
BRAKE PEDAL BR–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C
CIRCUIT INSPECTION
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP BO–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMBINATION METER BE–2. . . . . . . . . . . . . . . . . . . . . . . . . .
COMBUSTION TYPE POWER HEATER AC–9. . . . . . . . . . . .
COMPRESSOR AND MAGNETIC CLUTCH
(1CD–FTV) AC–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER FAN (1CD–FTV) AC–30. . . . . . . . . . . . . . . . . . . .
CURTAIN SHIELD AIRBAG ASSEMBLY RS–20. . . . . . . . . . . .
D
DIAGNOSTIC TROUBLE CODE CHART
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CASE (E251) MX–41. . . . . . . . . . . . . . . . . . . . .
DRIVE BELT SR–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT (1CD–FTV) AC–1. . . . . . . . . . . . . . . . . . . . . . . . .
E
ELECTRICAL TYPE POWER HEATER AC–23. . . . . . . . . . . . .
F
FOG LIGHT SYSTEM BE–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOR ALL OF VEHICLES IN–9. . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT SA–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
G
GENERAL INFORMATION
(HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS) IN–18. . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
(HOW TO USE THIS MANUAL) IN–1. . . . . . . . . . . . . . . . .
GENERAL INFORMATION
(REPAIR INSTRUCTIONS) IN–4. . . . . . . . . . . . . . . . . . . . .
H
HOW TO PROCEED WITH TROUBLESHOOTING
(HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS) IN–19. . . . . . . . . . . . . . . . . . . . . Page
HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS IN–18. . . . . . . . . . . . . . . . . . . . . .
HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE
(HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS) IN–29. . . . . . . . . . . . . . . . . . . . .
HOW TO USE THIS MANUAL IN–1. . . . . . . . . . . . . . . . . . . . .
I
IDENTIFICATION INFORMATION IN–3. . . . . . . . . . . . . . . . . .
INPUT SHAFT (E251) MX–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL BO–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
M
MANIFOLD GAUGE SET (1CD–FTV) AC–4. . . . . . . . . . . . . . .
MANUAL TRANSAXLE (E251)
(PREPARATION) PP–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE (E251)
(SERVICE SPECIFICATIONS) SS–4. . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE ASSEMBLY (E251) MX–9. . . . . . . . . .
MANUAL TRANSAXLE UNIT (E251) MX–2. . . . . . . . . . . . . . . .
O
OIL PUMP (E251) MX–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT (E251) MX–30. . . . . . . . . . . . . . . . . . . . . . . . . .
P
PARTS LOCATION
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING FLUID SR–3. . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING VANE PUMP
(2C–T, 2C–TE, 1CD–FTV) SR–6. . . . . . . . . . . . . . . . . . . . . .
PRE–CHECK
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION (FOR ALL OF VEHICLES) IN–9. . . . . . . . . . .
R
REFRIGERANT LINE AC–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY (1CD–FTV) AC–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS IN–4. . . . . . . . . . . . . . . . . . . . . . . . .
ROOF HEADLINING (Liftback) BO–27. . . . . . . . . . . . . . . . . . . . .
ROOF HEADLINING (Sedan) BO–22. . . . . . . . . . . . . . . . . . . . . .
ROOF HEADLINING (Wagon) BO–32. . . . . . . . . . . . . . . . . . . . .
S
SHIFT AND SELECT LEVER SHAFT (E251) MX–40. . . . . . . . .
SHIFT LEVER AND CONTROL CABLE (E251) MX–48. . . . . . .
SIDE AIRBAG ASSEMBLY RS–9. . . . . . . . . . . . . . . . . . . . . . . .
SIDE AND CURTAIN SHIELD AIRBAG SENSOR
ASSEMBLY RS–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SLIDING ROOF BO–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRS AIRBAG RS–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD BOLT (SERVICE SPECIFICATIONS) SS–1. . . .
STEERING (PREPARATION) PP–12. . . . . . . . . . . . . . . . . . . . . .
STEERING (SERVICE SPECIFICATIONS) SS–13. . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM
(DIAGNOSTICS) DI–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM
(PREPARATION) PP–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .