2003 TOYOTA AVENSIS oil pressure

2600P±03
F44620
G21679
26±26
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
STABILIZER BAR FRONT
REPLACEMENT
HINT:
COMPONENTS: See page 26±2
1. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and front stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut,use a hexagon wrench
(6 mm) to hold the stud.
3. REMOVE FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side. 4. INSPECT FRONT STABILIZER LINK ASSY LH
(a) As shown in the illustration, flip the ball joint stud back andforth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate
of 3 ± 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
5.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
6. SEPARATE TIE ROD END SUB±ASSY RH
SST 09628±62011
HINT:
Separate the RH side by the same procedures as the LH side.
7.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
8. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Separate the RH side by the same procedures as the LH side.
9. SEPARATE RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
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F45155
A
B
F44620
26±28
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
21. INSTALL FRONT STABILIZER BRACKET NO.1 RH
(a) w/ HID: Install the front stabilizer bracket No.1 RH and the height
control sensor (Front) with the 3 bolts.
Torque:
Bolt A: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
Bolt B: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b) w/o HID: Install the front stabilizer bracket No.1 RH with the 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
22.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±16)
23.INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH (See page 26±16)
24. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Install the RH side by the same procedures as the LH side.
25. INSTALL RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
26.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
27. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Connect the RH side by the same procedures as the LH side.
28.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
29. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Connect the RH side by the same procedures as the LH side.
30. INSTALL FRONT STABILIZER LINK ASSY LH
(a) Install the front stabilizer link assy LH with the 2 nuts.Torque: 74 N
m (755 kgf
cm, 55 ft
lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
31. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Install the RH side by the same procedures as the LH side.
32. INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
33.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
34.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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G24250
Vacuum HoseNew O±Ring
Oil Hose
F45366
Vacuum Gauge
±
BRAKE VACUUM PUMP ASSY (1CD±FTV)
32±39
AVENSIS REPAIR MANUAL (RM1018E)
17. INSTALL VACUUM PUMP ASSY
(a) Coat 2 new O±rings with engine oil, and install them to the
vacuum pump assy.
(b) Install the vacuum pump assy aligning the coupling with the slit of the camshaft.
(c) Install the 2 bolts. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(d) Connect 2 vacuum hoses and oil hose.
18. INSPECT CHECK VACUUM PUMP OPERATION
(a) Slide the clip, then disconnect the vacuum hose from vac- uum pump assy.
(b) Connect the hose of the vacuum gauge to the vacuum pump assy.
(c) Block off another hose of the vacuum gauge with the hose clamp No.2.
(d) Start the engine and warm it up for more than 2 minutes.
(e) With the engine idle, check the negative pressure of the vacuum pump assy.
Standard: More than 650 mmHg (86.7 kPa).
(f) Remove the vacuum gauge from the vacuum pump assy.
(g) Connect the vacuum hose with the clip to the vacuum pump assy.
19. INSTALL AIR CLEANER CAP SUB±ASSY
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4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26
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C62956
D30058
1CD±FTV Engine Type:Others:
Transaxle Side


D25281
AB
C62958
±
CLUTCH CLUTCH UNIT (MTM)
42±27
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE CLUTCH DISC ASSY
NOTICE:
Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub±assy
away from oil and foreign attachment.
9. INSPECT CLUTCH DISC ASSY
(a) Using vernier calipers, measure the rivet head depth.Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assy as necessary.
(b) Install the clutch disc assy to the transaxle assy.
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
(c) Using a dial gage, check the clutch disc assy runout. Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assy as necessary.
10. INSPECT CLUTCH COVER ASSY
(a) Using vernier calipers, inspect the diaphragm spring for
the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assy as necessary.
11. INSPECT FLYWHEEL SUB±ASSY
(a) Using a dial gage, inspect the flywheel sub±assy runout. Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub±assy as necessary.
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5006X−01
Steering
Column
Protector No.1
F44781
Horn Button Assy
Steering Wheel Assy
Spiral Cable Sub −Assy
Steering Column Cover
Headlamp Dimmer Switch AssySteering Column Assy
Steering
Sliding Yoke
Sub− Assy
Steering Intermediate
Shaft Assy No.2
Column Hole Cover Silencer Sheet
Steering Column Cover LWR
Windshield Wiper
Switch Assy
N

m (kgf
cm, ft
lbf): Specified torque
OIL Pressure Power Steering:
Steering Intermediate
Shaft Assy No.2
Steering
Sliding Yoke
Sub−Assy
35 (360, 26)
Column Hole Cover
Silencer Sheet
LHD Steering Position Type:
LHD Steering Position
Type: w/ Instrument Cluster
Finish Panel Assy
Floor Shift
Parking Lock Cable
Assy (A/T Transaxle)
Instrument Panel
Hole Cover
5 (51, 44 in.




lbf)
18 (184, 13)
18 (184, 13)
Instrument Panel
Airbag Assy
18 (184, 13)
18 (184, 13)
18 (184, 13)
25 (255, 18)
50 (510, 37)
35 (360, 26)
35 (360, 26)
28 (286, 21)
35 (360, 26)
28 (286, 21)
25 (255, 18)
25 (255, 18)
−
STEERING COLUMN STEERING COLUMN ASSY
50−5
STEERING COLUMN ASSY
COMPONENTS
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F44798
F44799
F44793Matchmarks
±
STEERING COLUMN STEERING COLUMN ASSY
50±15
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE UN±LOCK WARNING SWITCH ASSY
(a) Slide the unlock warning switch assy out of the steering column upper br\
acket.
39. REMOVE IGNITION OR STARTER SWITCH ASSY
(a) Remove the 2 screws and ignition or starter switch assy.
40. INSTALL IGNITION OR STARTER SWITCH ASSY
(a) Install the ignition or starter switch assy to the steering column upper w/swit\
ch bracket assy with the
2 screws.
41. INSTALL UN±LOCK WARNING SWITCH ASSY
(a) Install the un±lock warning switch assy.
(b) Connect the un±lock warning switch assy connector to the ignition or \
starter switch assy.
42. INSTALL IGNITION SWITCH LOCK CYLINDER ASSY
(a) Make sure of the ignition switch lock cylinder assy at the ACC position.\
(b) Install the ignition switch lock cylinder assy.
43. INSPECT STEERING LOCK OPERATION
(a) Check that the steering lock mechanism is activated when removing the ke\
y.
(b) Check that the steering lock mechanism is deactivated when inserting the\
key and turning it to ACC position.
44. INSTALL TRANSPONDER KEY AMPLIFIER
(a) Align the transponder key amplifier with the installationposition of the upper bracket with the amplifier inclined.
(b) Push the transponder key amplifier up and connect it to the upper bracket.
NOTICE:
Take care not to push the amplifier up with excessive force
to prevent it from being damaged.
45. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
(a) Temporarily install the steering column upper with switch bracket assy and steering column upper clamp with 2 new
tapered±head bolts.
(b) Tighten the 2 tapared±head bolts until the bolt heads break off.
46. INSTALL STEERING SLIDING YOKE SUB±ASSY (RHD STEERING POSITION TYPE)
(a) W/VSC:
Install the steering sensor (See page 32±65).
(b) Align matchmarks on the steering sliding yoke and steer- ing main shaft.
(c) Oil Pressure Power Steering
(1) Install the steering sliding yoke with the bolt.
Torque: 28 N
m (286 kgf
cm, 21 ft
lbf)
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F44793Matchmarks
F44789
RHD:
Matchmarks
A
B
F45709
50−16
−
STEERING COLUMN STEERING COLUMN ASSY
(d) Electric Pressure Power Steering
(1) Install the steering sliding yoke with the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
47. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (LHD STEERING POSITION TYPE)
(a) W/VSC:
Install the steering sensor (See page 32− 65).
(b) Align matchmarks on the steering intermediate shaft assy
No. 2 and steering main shaft.
(c) Oil Pressure Power Steering (1) Install the steering intermediate shaft assy No. 2
with the bolt.
Torque: 28 N
m (286 kgf
cm, 21 ft
lbf)
(d) Electric Pressure Power Steering (1) Install the steering intermediate shaft assy No. 2
with the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
48. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (RHD STEERING POSITION TYPE)
(a) Temporarily install the steering intermediate shaft assy No. 2 with the bolt A.
49. INSTALL STEERING SLIDING YOKE SUB −ASSY (LHD STEERING POSITION TYPE)
(a) Temporarily install the steering sliding yoke with the bolt A.
50. INSTALL STEERING COLUMN ASSY
(a) Install the steering column assembly with the 3 bolts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(b) RHD: Align the matchmarks on the intermediate shaft assy No.
2 and steering intermediate shaft.
(c) RHD: Install the bolt B and tighten the bolt A.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
HINT:
When replacing the intermediate shaft assy No. 2 with a new
one, set the front tires in the straight ahead position and make
the bolt hole for the intermediate shaft assy No. 2 and extension
face straight rearward as illustrated, and install the bolt.
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