2003 TOYOTA AVENSIS length

170FV±01
A56222
A56223
±
LUBRICATION OIL FILTER SUB±ASSY (1AZ±FSE)
17±19
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FSE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of nat\
ural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used \
engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or\
sol-
vents.

In order to preserve the environment, used oil and used oil filter must be\
disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil. Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter. SST 09228±06501
4. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn. SST 09228±06501
5. ADD ENGINE OIL
(a) Fill with fresh engine oil. Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. \
qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp.\
qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK
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2600L±02
F44617
Front:AB
F44618
Rear:
C D
SA3213
A
D B
Front
C
F44619
26±6
±
FRONT SUSPENSION FRONT WHEEL ALIGNMENT
AVENSIS REPAIR MANUAL (RM1018E)
FRONT WHEEL ALIGNMENT
ADJUSTMENT
1.INSPECT TIRE (See page 28±1) 2. MEASURE VEHICLE HEIGHT
Vehicle height:
(Normal package)
FrontA ± B: 92 mm (3.62 in.)
RearD ± C: 61 mm (2.40 in.)
(Rough road package)
FrontA ± B: 72 mm (2.83 in.)
RearD ± C: 41 mm (1.61 in.)
Measuring points:
A: Ground clearance of front wheel center
B: Ground clearance of lower suspension arm front bolt
center
C: Ground clearance of toe control arm inner bolt center
D: Ground clearance of rear wheel center
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specified value.
If the vehicle height is not the specified value, adjust it by push-
ing down or lifting the body.
3. INSPECT TOE±IN
Toe±in:
Toe±in(total)A + B: 0
06'  12' (0.1
 0.2
)
C ± D: 1  2 mm (0.04  0.08 in.)
If the toe±in is not within the specified value, adjust it at the rack
ends.
4. ADJUST TOE±IN
(a) Remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to
adjust the toe±in.
HINT:
Adjust the toe±in to the center of the specified value as much
as possible.
(d) Make sure that the lengths of the right and left rack ends are the same.
(e) Torque the tie rod end lock nuts.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
(f) Place the boots on the seats and install the clips.
HINT:
Make sure that the boots are not twisted.
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SA0028
ABFront AB
A: Inside
B: Outside
Z03382
Alignment
Tester Gauge
±
FRONT SUSPENSION FRONT WHEEL ALIGNMENT
26±7
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully and measure the turning
angle.
Wheel turning angle:
(Normal package)
Inside wheel
 17'  2 
\b
  \b

 47'  2 
\f
  \b\b
Outside wheel: Reference32 52'  \b
\f
315'  \b
\b
(Rough road package)
Inside wheel
 42'  2 
\f  \b
 09'  2  
  \b\b
Outside wheel: Reference33 16'  \b\f
3138'   \b
*1: Electric motor power steering models
*2: Oil pressure power steering models
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION
(a) Install the camber±caster±kingpin gauge or position the vehicle on the wheel alignment tester.
(b) Inspect the camber, caster and steering axis inclination.
Camber, caster and steering axis inclination:
(Normal package)
Camber
Right±left error±034'  45' (±0.57   0.75 )
45' (0.75 ) or less
Caster
Right±left error\b54'  45' (2.90   0.75 )
45' (0.75 ) or less
Steering axis inclination
Right±left error\b27'  45' (12.45   0.75 )
45' (0.75 ) or less
(Rough road package)
Camber
Right±left error±019'  45' (±0.32   0.75 )
45' (0.75 ) or less
Caster
Right±left error\b40'  45' (2.67   0.75 )
45' (0.75 ) or less
Steering axis inclination
Right±left error56'  45' (11.93   0.75 )
45' (0.75 ) or less
If the caster and steering axis inclination are not within the spe-
cified values, after the camber has been correctly adjusted, re-
check the suspension parts for damaged and/or worn out parts.
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270E1±01
SA3213
AD B
Front
C
G23862
27±4
±
REAR SUSPENSION REAR WHEEL ALIGNMENT
AVENSIS REPAIR MANUAL (RM1018E)
REAR WHEEL ALIGNMENT
ADJUSTMENT
1.INSPECT TIRE (See page 28±1)
2.MEASURE VEHICLE HEIGHT (See page 26±6)
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle height to the \
specified value. 3. INSPECT TOE±IN
Toe±in:
(Normal package)
Toe±in(total)A + B: 0 18' \b 12' (0.3  \b 0.2 )
C ± D: 3.0 \b 2.0 mm (0.12 \b 0.08 in.)
(Rough road package)
Toe±in
(total)A + B: 0 ' \b 12' (0.3  \b 0.2 )
C ± D: 3.0 \b 2.0 mm (0.12 \b 0.08 in.)
If the toe±in is not within the specified value, inspect the sus-
pension parts and replace them if necessary.
4. INSPECT CAMBER
(a) Install the camber±caster±kingpin gauge or position the vehicle on\
the wheel alignment tester.
(b) Inspect the camber.
Camber:
(Normal package)
Camber
Right±left error±0 ' \b 30' (±0.9  \b 0.5 )
30' (0.5 ) or less
(Rough road package)
Camber
Right±left error±0
' \b 30' (±0.5  \b 0.5 )
30' (0.5 ) or less
If the measured value is not within the specified value, inspect the suspension parts for damage and/or wear
and replace them if necessary because camber is not adjustable.
5. ADJUST CAMBER AND TOE±IN
(a) Measure the distance from the LH rear suspension armbracket assy set bolt to the RH rear axle carrier rear side
set bolt as shown in the illustration.
(b) Measure the distance from the RH rear suspension arm bracket assy set bolt to the LH rear axle carrier rear side
set bolt as shown in the illustration.
(c) Employ the same manner to the LH±RH.
Length difference: 6.0 mm (0.236 in.) or less
If the difference exceeds the specified value, adjust it by turning
the camber adjusting cam assy and tie rod adjusting tube.
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D29968
RHD:
LHD:
Fulcrum Length
Fulcrum Length
SST(s)
SST(s)
D29967
RHD:
LHD:
Fulcrum LengthFulcrum
Length
SST(s)
SST(s)
51±44
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
44.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
45. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
46.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
47. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side. 48. 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.
49. CONNECT STEERING GEAR OUTLET RETURN TUBE
(a) Using SST(s), connect the outlet return tube. 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) LHD: Install the tube clamp with bolt to the power steering gear
assy.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
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F40053
SST(s)
SST(s)
Fulcrum
LengthHold
Turn
C57755
F400843 mm (0.12 in.) or less SST(s)
±
POWER STEERING STEERING GEAR ASSY
51±31
AVENSIS REPAIR MANUAL (RM1018E)
34. INSTALL STEERING RACK END SUB±ASSY
(a) Using SST(s), hold the steering rack steadily and using
another SST(s), torque the rack end sub±assy.
SST 09922±10010
Torque: 60 N
m (616 kgf
cm, 45 ft
lbf)
NOTICE:
Use SST(s) 09922±10010 in the direction shown in the il-
lustration.
HINT:

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

Perform the same procedure on the other side.
35. INSTALL STEERING RACK BOOT NO.2
(a) Apply silicon grease to the inside small caliber of rack boot No.2.
(b) Install the rack boot No.2 to the groove on the rack hous- ing.
NOTICE:
Be careful not to damage or twist the boot.
36. INSTALL STEERING RACK BOOT NO.1
HINT:
Perform the same procedure on the other side. 37. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Install a new rack boot No.2 clamp to the rack boot No.2.
(b) Using SST(s), stake the rack boot No.2 clamp as shownin the illustration.
SST 09521±24010
38. INSTALL STEERING RACK BOOT NO.1 CLAMP SST 09521±24010
HINT:
Perform the same procedure on the other side.
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C65369
D30331
Cloth
F09875


D30332
LengthThickness
R10282
Feeler Gauge
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
51±21
AVENSIS REPAIR MANUAL (RM1018E)
(c) Remove the O±ring from the housing sub±assy front.
14. REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using a screwdriver, remove the housing oil seal.
NOTICE:
Be careful not to damage the pump housing.
15. 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.
16. 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.)
(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.)
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D30362Inscribed Mark

D30363


F41622
Compressed Air
51±22
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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)
17. 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.
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