2005 TOYOTA AVENSIS wheel torque

030G7±04
03±60
± SERVICE SPECIFICATIONSPOWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedN
mkgf
cmft
lbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356
81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in.
lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)

030G6±04
± SERVICE SPECIFICATIONSPOWER STEERING
03±59
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING
SERVICE DATA
POWER STEERING FLUID
Fluid level rise Maximum5 mm (0.20 in.)
Fluid pressure at idle speed with valve closed AZ Series:
1CD±FTV:8,300 to 9,000 kPa (85 to 92 kgf/cm2, 1,204 to 1,305 psi)
8,800 to 9,500 kPa (90 to 97 kgf/cm2, 1,276 to 1,378 psi)
STEERING WHEEL
Steering effort at idle speed (Reference)5.5 N´m (56 kgf´cm, 49 in.´lbf)
VANE PUMP ASSY
Vane pump rotating torque0.27 N´m (2.8 kgf´cm, 2.4 in.´lbf) or less
Vane pump shaft and vane pump housing oil clearance Maximum0.07 mm (0.0028 in.)
Vane plate thickness Minimum1.405 to 1.411 mm (0.05531 to 0.05555 in.)
Clearance between the rotor groove and plate Maximum0.03 mm (0.0012 in.)
Spring free length Minimum36.9 mm (1.453 in.)
STEERING GEAR ASSY
Total preload (Tie rod rotating torque) (Turning)0.29 to 1.96 N´m (3 to 20 kgf´cm, 2.57 to 17.35 in.´lbf)
Total preload (Control valve rotating torque) (Turning)0.6 to 1.1 N´m (6 to 11 kgf´cm, 5.3 to 9.7 in.´lbf)
RACK & PINION POWER STEERING GEAR ASSY
Total preload (Tie rod rotating torque) (Turning)0.49 to 3.43 N´m (5 to 35 kgf´cm, 4.34 to 30.38 in.´lbf)

031FZ±01
03±58
± SERVICE SPECIFICATIONSSTEERING COLUMN
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Steering intermediate shaft assy No. 2 x Oil pressure power steering
column assy (LHD steering positoin type)2828621
Steering sliding yoke sub±assy x Oil pressure power steering column assy
(RHD steering positoin type)2828621
Steering intermediate shaft assy No. 2 x Electric power steering column
assy (LHD steering positoin type)3536026
Steering sliding yoke sub±assy x Electric power steering column assy
(RHD steering positoin type)3536026
Steering sliding yoke sub±assy x Steering intermediate shaft assy No. 23536026
Steering column assy set bolt2121415
Steering sliding yoke sub±assy x Steering gear assy
(LHD steering positoin type)3536026
Steering intermediate shaft assy No. 2 x Steering gear assy
(RHD steering positoin type)3536026
Steering wheel set nut5051037
Steering wheel pad set screw (Torx screw)8.89078 in.´lbf
Steering column cover LWR x Steering column assy5.05144 in.´lbf
Instrument panel airbag assy1818413
Power steering ECU assy (Bolt A)88271 in.´lbf
Power steering ECU assy (Bolt B)15.515811

030L2±04
03±56
± SERVICE SPECIFICATIONSCLUTCH
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Clutch pedal support x Stopper bolt2525018
Clutch pedal sub±assy x Clutch pedal support3737527
Clutch pedal support x Body1919514
Clutch pedal support x Clutch start switch assy1616012
Clutch master cylinder push rod clevis lock nut121209
Clutch master cylinder x Flexible hose tube1515511
Clutch master cylinder x Body121209
Clutch release cylinder bleeder plug8.48574 in.
lbf
Clutch release cylinder x Transaxle housing
1CD±FTV/1AZ±FSE/1AZ±FE engine type
121209
Clutch release cylinder x Transaxle housing 1ZZ±FE/3ZZ±FE engine type1414110
Clutch release cylinder x Flexible hose tube bracket
1ZZ±FE/3ZZ±FE engine type
5.05144 in.
lbf
Clutch release cylinder x Clutch line clamp 1AZ±FSE/1AZ±FE engine type121229
Clutch release cylinder x Flexible hose tube1515511
Clutch release cylinder x Clutch accumulator assy 1CD±FTV engine type121209
Clutch accumulator assy x Flexible hose tube 1CD±FTV engine type1515511
Clutch cover assy x Flywheel sub±assy1919514
Release fork support x Transaxle assy 1AZ±FSE/1AZ±FE engine type
1ZZ±FE/3ZZ±FE/1CD±FTV engine type48
37480
37535
27

D25148
TA CDLC3 12345 768
9 1 0111 21 3 1 514 16
± DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E(1AZ±FE))05±871
AVENSIS REPAIR MANUAL (RM1018E)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R ranges.
NOTICE:

Do the test at normal operating ATF temperature 50 to 80
C (122 to 176
F).

Do not continuously run this test for longer than 5 seconds.

To ensure safety, do this test in a wide, clear level area which provides good traction.

The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect the hand±held tester to DLC3 or tachome-
ter to terminal TAC of DLC3 with SST.
SST 09843±18030
(3) Fully apply the parking brake.
(4) Keep your left foot pressing firmly on the brake ped-
al.
(5) Start the engine.
(6) Shift into the D range. Press all the way down on the
accelerator pedal with your right foot.
(7) Quickly read the stall speed at this time.
Stall speed: 2,550
150 rpm
(8) Do the same test in the R range.
Stall speed: 2,550
150 rpm
Evaluation:
ProblemPossible cause
(a) Stall speed low in D and R ranges

Engine output may be insufficient

Stator one±way clutch not operating properly
HINT: If more than 600 rpm below the specified value, the torque
converter could be faulty.
(b) Stall speed high in D range

Line pressure too low

Forward clutch slipping

No. 2 one±way clutch not operating properly

U/D clutch slipping
(c) Stall speed high in R range

Line pressure too low

Direct clutch slipping

1st & reverse brake slipping

U/D clutch slipping
(d) Stall speed high in D and R ranges

Line pressure too low

Improper fluid level

U/D one±way clutch not operating properly

D25148
TA CDLC3 12345 768
9 1 0111 21 3 1 514 16 05±926
± DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E(1AZ±FSE))
AVENSIS REPAIR MANUAL (RM1018E)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R ranges.
NOTICE:

Do the test at normal operating ATF temperature 50 to 80
C (122 to 176
F).

Do not continuously run this test for longer than 5 seconds.

To ensure safety, do this test in a wide, clear level area which provides good traction.

The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect the hand±held tester to DLC3 or tachome-
ter to terminal TAC of DLC3 with SST.
SST 09843±18030
(3) Fully apply the parking brake.
(4) Keep your left foot pressing firmly on the brake ped-
al.
(5) Start the engine.
(6) Shift into the D range. Press all the way down on the
accelerator pedal with your right foot.
(7) Quickly read the stall speed at this time.
Stall speed: 2,550
150 rpm
(8) Do the same test in the R range.
Stall speed: 2,550
150 rpm
Evaluation:
ProblemPossible cause
(a) Stall speed low in D and R ranges

Engine output may be insufficient

Stator one±way clutch not operating properly
HINT: If more than 600 rpm below the specified value, the torque
converter could be faulty.
(b) Stall speed high in D range

Line pressure too low

Forward clutch slipping

No. 2 one±way clutch not operating properly

U/D clutch slipping
(c) Stall speed high in R range

Line pressure too low

Direct clutch slipping

1st and reverse brake slipping

U/D clutch slipping
(d) Stall speed high in D and R ranges

Line pressure too low

Improper fluid level

U/D one±way clutch not operating properly

F44868
Power Steering ECU Assy Torque Sensor
TRQV
TRQ1
TRQ2
TRQG 6
5
7
8
± DIAGNOSTICSELECTRONIC MOTOR POWER STEERING SYSTEM
05±1059
AVENSIS REPAIR MANUAL (RM1018E)
DTC C1511/11 Torque Sensor Circuit Malfunction
DTC C1512/12 Torque Sensor Circuit Malfunction
DTC C1513/13 Torque Sensor Circuit Malfunction
DTC C1514/14 Torque Sensor Power Source Circuit
Malfunction
DTC C1517/17 Torque Sensor Hold Malfunction
CIRCUIT DESCRIPTION
The torque sensor converts the power input in the steering wheel into electric signals, and sends them to
the ECU.
DTC No.DTC Detecting ConditionTrouble Area
C1511/11
C1512/12Torque sensor circuit malfunction
C1513/13
q
Steering column assy

Power steering ECU assy
C1514/14Torque sensor power source circuit malfunction

Power steering ECU assy
C1517/17Torque sensor hold malfunction
WIRING DIAGRAM
05C5H±01

05±1060
±
DIAGNOSTICS ELECTRONIC MOTOR POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
NOTICE:
When performing the inspection of power steering ECU, ECU must be instal\
led to the vehicle or fully
fixed.
HINT:
Start the inspection from the step 1 with using hand±held tester. Start from step 2 without using hand±held
tester.
1READ VALUE OF HAND±HELD TESTER
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch to ON and push the hand±held tester main swit\
ch ON.
(c)Select the item ºTRQ1º and ºTRQ2º in the DATA LIST and read its value displayed on the hand±held tester.
(d)Check the values on the ºTRQ1º and ºTRQ2º of the data monito\
r with the steering wheel being in the center value position (no load).
Standard:
2.3 to 2.7 V
(e)Check the difference of the values between ºTRQ1º and ºTRQ2º with the steering wheel being in the center value position (no load).
Standard:
Voltage: 0.3 V or less
(f)Check the values of the torque sensor on the data monitor when turning s\
teering wheel. (1)Turn the steering wheel to the right end from the center value position, and check the values on\
the ºTRQ1º and ºTRQ2º of the data monitor.
Standard:
2.5 to 4.7 V
(2)Turn the steering wheel to the left end from the center value position, and \
check the values on the ºTRQ1º and ºTRQ2º of the data monitor.
Standard:
0.3 to 2.5 V
(3)Check the difference of the values between ºTRQ1º and ºTRQ2º.
Standard:
Voltage: 0.3 V or less
NGGo to step 3
OK
REPLACE POWER STEERING ECU ASSY (See page 50±20)