Page 1545 of 1897
PP0S3-01
PP-24
- PREPARATIONSTARTING
74 Author: Date:
2001 AVALON (RM808U)
EQUIPMENT
Dial indicatorCommutator
Magnetic fingerSteel ball
PressMagnetic switch terminal kit
Pull scaleBrush spring
SandpaperCommutator
Torque wrench
V-blockCommutator
Vernier calipersCommutator, Brush
Page 1558 of 1897
SS0FT-05
- SERVICE SPECIFICATIONSBRAKE
SS-31
147 Author: Date:
2001 AVALON (RM808U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt w/o VSC101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut 10 mm
12 mm15
20155
20011
15
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket131309
Brake pedal x Pedal bracket3940029
Front brake caliper installation bolt3435025
Bleeder plug8.38574 in.´lbf
Front brake torque plate x Steering knuckle1071,09079
Front brake caliper x Flexible hose2930022
Flexible hose x Shock absorber bracket2930022
Rear brake caliper installation bolt3435025
Rear brake caliper x Flexible hose2930022
Rear brake torque plate x Rear axle carrier4747534
Parking brake pedal bracket x Body6162045
ABS actuator x ABS actuator bracket131309
ABS actuator x ECU3.03127 in.´lbf
ABS & VSC actuator x Actuator bracket131309
ABS (& VSC) actuator bracket x Body1919514
Front speed sensor installation bolt8.08271 in.´lbf
Rear speed sensor installation bolt8.08271 in.´lbf
ABS speed sensor harness clamp bolt5.45548 in.´lbf
Precharge pump x Precharge pump bracket Bolt
Nut8.0
1382
13071 in.´lbf
9
Precharge pump brackt x Body1919514
Precharge pump x Master cylinder pressure sensor8183060
Page 1577 of 1897
SS04X-06
SS-28
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
144 Author: Date:
2001 AVALON (RM808U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT AXLE
Hub nut1031,05076
Tie rod end lock nut7475054
Steering knuckle x Shock absorber2112,150156
Steering knuckle x Brake caliper1071,09079
Steering knuckle x Tie rod end4950036
Axle hub x Drive shaft2943,000217
Lower ball joint x Lower suspension arm1271,30094
Lower ball joint x Steering knuckle1231,25090
Steering knuckle x Dust cover8.38574 in.´lbf
ABS speed sensor set bolt8.08271 in.´lbf
FRONT DRIVE SHAFT
Drive shaft center bearing lock bolt3233024
FRONT SUSPENSION
Suspension support x Body8082059
Suspension support x Piston rod4950036
Flexible hose and ABS speed sensor wire harness x Shock absorber2930022
Lower suspension arm set bolt2062,100152
Stabilizer bar bracket x Suspension member1919514
Stabilizer bar link set nut3940029
REAR AXLE
Hub nut1031,05076
Brake caliper x Rear axle carrier4747534
Axle hub set bolt8082059
Shock absorber x Rear axle carrier New nut
Reused nut (Apply engine oil to the threads.)255
1962,600
2,000188
145
No. 1, No. 2 lower suspension arm x Rear axle carrier1811,850134
Strut rod x Rear axle carrier11 31,15083
ABS speed sensor set bolt8.08271 in.´lbf
REAR SUSPENSION
ABS speed sensor wire harness x Shock absorber5.45548 in.´lbf
Flexible hose x Shock absorber2930022
Rear seat belt set bolt4142030
Rear seatback set bolt1818513
Suspension support x Body3940029
Suspension support x Piston rod4950036
Center exhaust pipe set bolt4344032
Parking brake cable set bolt5.45548 in.´lbf
No. 2 lower suspension arm lock nut5657041
No. 1, No. 2 lower suspension arm x Suspension member1811,850134
Strut rod x Body11 31,15083
Suspension member x Body5152038
Suspension member lower stopper x Body3839028
Page 1761 of 1897
P10584
Ohmmeter
Continuity
ST04Q-02
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
ST-8
- STARTINGSTARTER
1261 Author: Date:
2001 AVALON (RM808U)
INSPECTION
1. INSPECT ARMATURE COIL
(a) Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
(b) Check the commutator for ground
Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
2. INSPECT COMMUTATOR
(a) Check the commutator for dirty and burnt surfaces.
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.
(b) Check the commutator circle runout.
(1) Place the commutator on V-blocks.
(2) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
(c) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.142 in.)
If the diameter is less than minimum, replace the armature.
(d) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.
Page 1762 of 1897
P10588
Ohmmeter
Continuity
P10589
Ohmmeter
No Continuity
Z10079
Brush Holder Side
Field Flame Side Length
Length
ST0019
- STARTINGSTARTER
ST-9
1262 Author: Date:
2001 AVALON (RM808U)
3. INSPECT FIELD COIL
(a) Check the field coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
(b) Check the field coil for ground.
Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, repair or replace the field frame.
4. INSPECT BRUSHES
Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 10 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and
field frame.
5. INSPECT BRUSH SPRINGS
Check the brush spring road.
Take the pull scale reading the instant the brush spring
separates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.79 - 2.41 kgf, 4.0 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.20 kgf, 2.7 lbf)
If the installed load is less than minimum replace the brush
springs.
Page 1770 of 1897
B01234
B01235
B01236
SST
B06430
(1)
(2)(4)
(5)
(6)
Inside
Identation
ProtrusionLong
Short
(3)
(7)
ST-14
- STARTINGSTARTER
1267 Author: Date:
2001 AVALON (RM808U)
4. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the 3 bolts, end cover, gasket and plunger.
(b) Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove the terminal kit parts
(1) Using SST, loosen the terminal nuts.
SST 09810-38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O- ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O-ring, terminal bolt,
contact plate, terminal insulator (inside).
(d) Install new terminal 30 kit parts.
(1) Temporarily install a new terminal insulator (inside).
(2) Temporarily install a new contact plate.
(3) Temporarily install a new terminal bolt.
(4) Temporarily install a new O-ring.
(5) Temporarily install a new packing and a new termi-
nal insulator (outside).
Install a new packing to a new terminal insulator,
and install them.
Page 1805 of 1897
SR0RT-02
R15196
Caliper Gauge
Micrometer
Vane Pump Shaft
Bushing
Front Housing
N00372
Thickness
Length Height
R10282
Feeler Gauge
- STEERINGPOWER STEERING VANE PUMP
SR-29
1492 Author: Date:
2001 AVALON (RM808U)
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:
0.03 - 0.05 mm (0.0012 - 0.0020 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 vane plates.
Minimum height: 8.6 mm (0.339 in.)
Minimum thickness: 1.397 mm (0.0550 in.)
Minimum length: 14.991 mm (0.5902 in.)
(b) Using a feeler gauge, measure the clearance between
the vane pump rotor groove and vane plate.
Maximum clearance: 0.035 mm (0.0014 in.)
Page 1807 of 1897
R08702
Vernier Calipers
- STEERINGPOWER STEERING VANE PUMP
SR-31
1494 Author: Date:
2001 AVALON (RM808U)
4. INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 32.3 mm (1.272 in.)
If it is not within the specification, replace the spring.
