2001 TOYOTA AVALON power steering

- PREPARATIONSTEERING
PP-43
93 Author
: Date
:
2001 AVALON (RM808U)
09631-12071Steering Rack Oil Seal Test ToolPS gear
09631-20081Seal Ring ToolPS gear
09631-33010Steering Rack Cover ºIºPS gear
09640-10010Power Steering Pressure Gauge
SetPower steering fluid
(09641-01010)Gauge Assy
(09641-01030)Attachment B
(09641-01060)Attachment E
09910-00015Puller SetTilt steering column
(09911-0001 1)Puller Clamp
(09912-00010)Puller Slide Hammer
09922-10010Variable Open WrenchPS gear
09950-50012Puller C SetTilt steering column
(09951-05010)Hanger 150

SS0G9-03
SS-32
- SERVICE SPECIFICATIONSSTEERING
148 Author
: Date
:
2001 AVALON (RM808U)
STEERING
SERVICE DATA
DRIVE BELT
Drive belt tension* New belt120 - 185 lbf
Drive belt tension* Used belt95 - 135 lbf
POWER STEERING FLUID
Fluid level rise Maximum5 mm (0.20 in.)
Fluid pressure at idle speed with valve closed Minimum7,845 kPa (80 kgf/cm2, 1,138 psi)
STEERING WHEEL
Steering wheel freeplayMaximum30 mm (1.18 in.)
Steering effort at idle speedReference5.9 N´m (60 kgf´cm, 52 in.´lbf)
POWER STEERING VANE PUMP
Vane pump rotating torque0.3 N´m (2.8 kgf´cm, 2.4 in.´lbf) or less
Oil clearance between pump shaft and bushing STD0.03 - 0.05 mm (0.0012 - 0.0020 in.)
Oil clearance between pump shaft and bushingMaximum0.07 mm (0.0028 in.)
Vane plate heightMinimum8.6 mm (0.339 in.)
Vane plate thickness Minimum1.397 mm (0.0550 in.)
Vane plate lengthMinimum14.991 mm (0.5902 in.)
Clearance between the rotor groove and plateMaximum0.035 mm (0.0014 in.)
Vane plate length Pump rotor and cam ring mark
None14.999 - 15.001 mm (0.59051 - 0.59059 in.)
114.997 - 14.999 mm (0.59043 - 0.59051 in.)
214.995 - 14.997 mm (0.59035 - 0.59043 in.)
314.993 - 14.995 mm (0.59027 - 0.59035 in.)
414.991 - 14.993 mm (0.59020 - 0.59027 in.)
Spring free length Minimum32.3 mm (1.272 in.)
POWER STEERING GEAR
Steering rack runout Maximum0.03 mm (0.0012 in.)
Total preload (Control valve rotating torque)0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
*: For use with belt tension gauge

SS0GA-06
- SERVICE SPECIFICATIONSSTEERING
SS-33
149 Author
: Date
:
2001 AVALON (RM808U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
TILT STEERING COLUMN
Tilt lever lock shaft9.09078 in.´lbf
Turn signal bracket x Steering column upper tube7.57565 in.´lbf
Shift lever housing x Column tube assembly101007
Shift lever set bolt1111 08
Shift lock solenoid bracket x Shift lever housing3.43530 in.´lbf
Shift lock switch guide2.82925 in.´lbf
Universal joint assembly x Main shaft assembly3536026
Steering column assembly set nut2526019
Intermediate shaft sub-assembly x Control valve shaft3536026
Universal joint assembly x Intermediate shaft sub-assembly3536026
Steering wheel set nut5051037
Steering wheel pad set screw (Torx screw)8.89078 in.´lbf
POWER STEERING VANE PUMP
Rear housing set bolt1717012
Pressure port union8385062
Suction port union set bolt131309
Front bracket x Rear bracket4344032
Vane pump pulley set nut4445033
Pressure feed tube x PS vane pump assembly5253038
Oil pressure switch2121015
PS vane pump set bolt A bolt29 (43)300 (440)22 (32)
PS vane pump set bolt B bolt4344032
Pressure feed tube x Pressure feed tube23 (25)230 (250)17 (18)
Clamp plate set nut7.88069 in.´lbf
POWER STEERING GEAR
Control valve housing set bolt1818013
Self-locking nut2525018
Rack housing cap5960043
Rack guide spring cap lock nut50 (69)510 (700)37 (51)
Rack x Rack end60 (83)610 (850)45 (61)
Tie rod end lock nut7475054
Turn pressure tube union nut12 (13)120 (130)9 (9)
PS gear assembly set bolt1811,850134
Stabilizer bar set bolt1919014
Pressure feed and return tubes x Control valve housing28 (25)290 (250)21 (18)
Pressure feed tube clamp plate set nut101007
Intermediate shaft sub-assembly x Control valve shaft3536026
Tie rod end x Steering knuckle4950036
( ): For use without SST

AB0089
Secondary Lock
Primary LockLockLock
Primary Lock Incomplete
(Secondary Lock Prevented)Primary Lock Complete
(Secondary Lock Permitted)Twin-Lock Completed
Z14034
Fig.1
Fig.2Power Source
Safing
Sensor
Squibs
Deceleration Sensor RS-8
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
1528 Author
: Date
:
2001 AVALON (RM808U)
(4) Connector Twin-Lock Mechanism
With this mechanism connectors (male and female
connectors) are locked by 2 locking devices to in-
crease the connection reliability. If the primary lock
is incomplete, ribs interfere and prevent the sec-
ondary lock.
(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.
Bag inflation then ends, and the bags deflate as the gas
is discharged through discharge holes at the bag's rear or
side.

RS01Y-34
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS-1
1521 Author
: Date
:
2001 AVALON (RM808U)
SRS AIRBAG
PRECAUTION
CAUTION:

The AVALON is equipped with SRS, which comprises a driver airbag, front passenger airbag
and side airbag. Failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Fur-
ther, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate
when required. Before performing servicing (including removal or installation of parts, inspec-
tion or replacement), be sure to read the following items carefully, then follow the correct proce-
dures described in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the ºLOCKº position and
the negative (-) terminal cable is disconnected from the battery.
(The SRS is equipped with a back-up power source so that if work is started within 90 seconds
from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)

Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly,
airbag sensor assembly, front airbag sensor or side airbag sensor assembly directly to hot air
or flames.
NOTICE:

Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sen-
sor and side airbag sensor assembly should be inspected.
(See page RS-15, RS-30, RS-44, RS-57, RS-64, RS-69, RS-74 and RS-79)

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side
airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly
in order to reuse it.

If the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sen-
sor assembly, front airbag sensor or side airbag sensor assembly has been dropped, or if there
are cracks, dents or other defects in the case, bracket or connector, replace it with new one.

Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting the system's
electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.

After work on the SRS is completed, perform the SRS warning light check (See page DI-349).

When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. This vehicle has power seat which are all equipped with
memory function. However, it is not possible to make a record of the memory contents. So when
the work is finished, it will be necessary to explain this fact to the customer, and ask the custom-
er to adjust the features and reset the memory. To avoid erasing the memory in each memory
system, never use a back- up power supply from outside the vehicle.

RS0L5-01
AB0152
SST
AB0158
SSTBattery
- SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS-17
1537 Author
: Date
:
2001 AVALON (RM808U)
DISPOSAL
HINT:
When scrapping vehicle equipped with an SRS or disposing of
a steering wheel pad (with airbag), always first deploy the air-
bag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the
SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
CAUTION:

Never dispose of a steering wheel pad which has an
undeployed airbag.

The airbag produces a sizeable exploding sound
when it deploys, so perform the operation out-of-
doors and where it will not create a nuisance to
nearby residents.

When deploying the airbag, always use the specified
SST (SRS Airbag Deployment Tool). Perform the op-
eration in a place away from electrical noise.
SST 09082-00700

When deploying an airbag, perform the operation at
least 10 m (33 ft) away from the steering wheel pad.

The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.

Use gloves and safety glasses when handling a steer-
ing wheel pad with the deployed airbag.

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to a steering wheel pad with
the deployed airbag.
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-
HICLE
HINT:
Have a battery ready as the power source to deploy the airbag.

R13455
10 m (33 ft) or more
SSTBattery
R06753
- SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS-19
1539 Author
: Date
:
2001 AVALON (RM808U)
(4) Move the SST at least 10 m (33 ft) away from the
front of the vehicle.
(5) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(6) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the negative (-) termi-
nal.
(c) Deploy the airbag.
(1) Check that no one is inside the vehicle or within 10
m (33 ft) area around the vehicle.
(2) Press the SST activation switch and deploy the air-
bag.
CAUTION:

The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.

Use gloves and safety glasses when handling a steer-
ing wheel pad with the deployed airbag.

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to a steering wheel pad with
the deployed airbag.

When scrapping a vehicle, deploy the airbag and
scrap the vehicle with the steering wheel pad still
installed.

When moving a vehicle for scrapping which has a
steering wheel pad with deployed airbag, use gloves
and safety glasses.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
2. DEPLOYMENT WHEN DISPOSING OF STEERING
WHEEL PAD ONLY
NOTICE:

When disposing of the steering wheel pad (with air-
bag) only, never use the customers vehicle to deploy
the airbag.

Be sure to follow the procedure given below when de-
ploying the airbag.
HINT:
Have a battery ready as the power source to deploy the airbag.

SR0EE-03
R11741
Normal Abnormal SR-4
- STEERINGPOWER STEERING FLUID
1467 Author
: Date
:
2001 AVALON (RM808U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR-5)
2. 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. LOWER VEHICLE
5. 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
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-5)