2002 TOYOTA AVENSIS Repair Manual


D30361
D30580
B
B
B
A
D30581
Fulcrum
Length
SST(s)
51±26
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
28. INSTALL FLOW CONTROL VALVE ASSY
(a) Coat the compression spring and the flow control valve assy with power steering fluid.
(b) Install the compression spring and the flow control valve assy.
(c) Coat a new O±ring with power steering fluid and install it onto the pressure port union sub±assy.
(d) Install the pressure port union sub±assy. Torque: 69 N
m (704 kgf
cm, 51 ft
lbf)
29. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O±ring with power steering fluid, and install it to the su\
ction port union.
(b) Install the suction port union with the bolt. Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
30. INSTALL VANE PUMP ASSY
(a) Install the vane pump assy and vane pump bracket rear with the 4 bolts.
Torque:
Bolt A: 72 N
m (734 kgf
cm, 53 ft
lbf)
Bolt B: 39 N
m (398 kgf
cm, 29 ft
lbf)
31. CONNECT PRESSURE FEED TUBE ASSY
(a) Using SST(s), connect the pressure feed tube assy. SST 09023±12700
Torque: 41 N
m (414 kgf
cm, 30 ft
lbf)
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).

This torque value is effective when SST(s) is parallel to a
torque wrench.
(b) Install the tube clamp with the bolt. Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
32. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No. 1 with the clip.
NOTICE:
Take care not to spill fluid on the V belt.
33. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
34. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55±46)
35.ADD POWER STEERING FLUID (See page 51±4)
36.BLEED POWER STEERING FLUID (See page 51±4)
37.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
38. INSPECT FLUID LEAK

510DF±02
F42473
Power Steering
Suction Port Union
O±ring

w/pulley Shaft Sub±assy
Vane Pump Side
Plate Front
Vane Pump Cam Ring10


Nm (kgfcm, ftlbf) : Specified torque
Non±reusable part

Power steering fluid
Pump Bracket Rear
Flow Control Valve Assy


Flow Control Valve
Compression Spring
44 (449, 32)
Vane Pump Housing
Sub±assy RearVane Pump Housing
Sub±assy Front


Vane Pump Rotor
Vane Pump Plate
22 (224, 16)
Vane Pump Housing
Oil Seal

Power Steering
Oil Pressure Switch
21 (214, 15)
69 (704, 51)
Vane Pump
Shaft Snap Ring
O±ring
O±ring
O±ring
22 (224, 16)
Pressure Port Union
Sub±assy
12 (122, 9)
51±8
± POWER STEERINGVANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
VANE PUMP ASSY (AZ Series)
COMPONENTS

510DG±02
F40529
Turn
Hold
D30330
SST(s)
A
B
F40247
SST(s)
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±9
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
NOTICE:

When using a vise, do not over tighten.

When installing, coat the parts indicated by the arrows with power steer\
ing fluid
(See page 51±8).
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE FAN AND GENERATOR V BELT 1AZ±FE: (See page 14±105)
1AZ±FSE: (See page 14±185)
4. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Remove the clip and disconnect the oil reservoir to pump hose No.1.
NOTICE:
Take care not to spill fluid on the V belt.
5. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Remove the bolt and separate the pressure feed tubeassy from the pump bracket rear.
(b) Using a spanner (27 mm) to hold the pressure port union, remove the union bolt and gasket.
6. REMOVE VANE PUMP ASSY
(a) Disconnect the connector from the oil pressure switch.
(b) Using SST(s) and a deep socket (14 mm), loosen the bolt A.
SST 09249±63010
(c) Remove the bolt B and vane pump assy.
7. FIX VANE PUMP ASSY
(a) Using SST(s), hold the vane pump assy in a vise. SST 09630±00014 (09631±00132)
8. REMOVE PUMP BRACKET REAR
(a) Remove the bolt and vane pump bracket rear.

F42475
C84483
C57767
51±10
± POWER STEERINGVANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
9. REMOVE POWER STEERING SUCTION PORT UNION
(a) Remove the bolt and the suction port union.
(b) Remove the O±ring from the suction port union.
10. REMOVE FLOW CONTROL VALVE ASSY
(a) Remove the pressure port union sub±assy.
(b) Remove the O±ring from the pressure port union sub±
assy.
(c) Remove the flow control valve assy and the compression
spring.
11. REMOVE POWER STEERING OIL PRESSURE SWITCH
NOTICE:
If the oil pressure switch is dropped or damaged, replace it with a new one.
12. REMOVE VANE PUMP HOUSING SUB±ASSY REAR
(a) Remove the 4 bolts and housing sub±assy rear from the
housing sub±assy front.
(b) Remove the O±ring from the housing sub±assy rear.
13. REMOVE W/PULLEY SHAFT SUB±ASSY
(a) Using 2 screwdrivers, remove the snap ring from the w/
pulley shaft sub±assy.
(b) Remove the w/pulley shaft sub±assy.
14. REMOVE VANE PUMP ROTOR
(a) Remove the 10 vane pump plates.
(b) Remove the vane pump rotor.
15. REMOVE VANE PUMP CAM RING

C65368
C65369
D30331
Cloth
F09875


D30332
LengthThickness
± POWER STEERINGVANE PUMP ASSY (AZ Series)
51±11
AVENSIS REPAIR MANUAL (RM1018E)
16. REMOVE VANE PUMP SIDE PLATE FRONT
(a) Remove the side plate front from the housing sub±assy
front.
(b) Remove the O±ring from the side plate front.
(c) Remove the O±ring from the housing sub±assy front.
17. REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using a screwdriver, remove the housing oil seal.
NOTICE:
Be careful not to damage the pump housing.
18. INSPECT VANE PUMP SHAFT AND BUSH IN
HOUSING FRONT
(a) Using a micrometer and a caliper gauge, measure the oil
clearance.
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the vane pump assy.
19. INSPECT VANE PUMP ROTOR AND VANE PUMP
PLATES
(a) Using a micrometer, measure the thickness of the vane
pump plates.
Minimum thickness:
1.405 to 1.411 mm (0.05531 to 0.05555 in.)

R10282
Feeler Gauge
D30362Inscribed Mark
F41493


F41622
Compressed Air 51±12
± POWER STEERINGVANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Using a feeler gauge, measure the clearance between a
side face of the vane pump rotor groove and vane plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the vane pump plate
and/or vane pump rotor with the one having the same mark as
stamped on the cam ring.
Inscribed mark: 0, 1, 2, 3 or 4
HINT:
There are 5 different marks for vane pump plate.
MarkPart numberLength mm (in.)
044345±0211012.001 to 12.003
(0.47247 to 0.47255)
144345±0212011.999 to 12.000
(0.47240 to 0.47244)
244345±0213011.997 to 11.998
(0.47232 to 0.47236)
344345±0214011.995 to 11.996
(0.47224 to 0.47228)
444345±0215011.993 to 11.994
(0.47216 to 0.47220)
20. INSPECT FLOW CONTROL VALVE ASSY
(a) Coat the flow control valve assy with power steering fluid
and check that it falls smoothly into the flow control valve
hole by its own weight.
If necessary, replace the vane pump assy.
(b) Check the flow control valve assy for leakage. Close one
of the holes and apply compressed air of 392 to 490 kPa
(4 to 5 kgf
cm
2, 57 to 71 psi) into the opposite side hole,
and confirm that air does not come out from the end holes.

D31004
Inscribed Mark
R08702
Vernier Calipers
F08480
SST(s)
Oil Seal

D30334
Vinyl Tape
± POWER STEERINGVANE PUMP ASSY (AZ Series)
51±13
AVENSIS REPAIR MANUAL (RM1018E)
If necessary, replace the flow control valve assy with the one
having the same letter as inscribed on the housing sub±assy
front.
Inscribed mark: A, B, C, D, E or F
HINT:
There are 6 different marks for flow control valve assy.
MarkPart number
A44330±05130
B44330±05140
C44330±05150
D44330±05160
E44330±05170
F44330±05180
21. INSPECT FLOW CONTROL VALVE COMPRESSION
SPRING
(a) Using vernier calipers, measure the free length of the
compression spring.
Minimum free length: 36.9 mm ( 1.453 in.)
If it is less than the minimum, replace the compression spring.
22. INSPECT PRESSURE PORT UNION SUB±ASSY
(a) If the union seat in the pressure port union sub±assy is remarkably damaged, it may cause fluid leak-
age. Replace the pressure port union sub±assy.
23. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new housing oil seal lip with power steering fluid.
(b) Using SST(s) and a press, install a new housing oil seal.
SST 09950±60010 (09951±00280), 09950±70010
(09951±07100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
24. INSTALL W/PULLEY SHAFT SUB±ASSY
(a) Coat inside bushing surface of the housing sub±assy
front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub±assy.
NOTICE:
Do not damage the oil seal lip.
HINT:
Tape the shaft before inserting.

C65369
C65368
F08482
Housing
Sub±assy Front Side Plate Front
F08483
Inscribed Mark
C95038
51±14
± POWER STEERINGVANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
25. INSTALL VANE PUMP SIDE PLATE FRONT
(a) Coat a new O±ring with power steering fluid and install it
into the housing sub±assy front.
(b) Coat a new O±ring with power steering fluid and install it
onto the side plate front.
(c) Align the dent of the side plate front with that of the hous-
ing sub±assy front, and install the side plate front.
NOTICE:
Make sure that the side plate front is installed facing in the
correct direction.
26. INSTALL VANE PUMP CAM RING
(a) Align the dent of the cam ring with that of the side plate
front, and install the cam ring with the inscribed mark fac-
ing upward.
27. INSTALL VANE PUMP ROTOR
(a) Install the vane pump rotor.