Page 2849 of 5135

C94598
C94596
A
BB
B
LH:
C94597
A
BB
B
RH:
C94595
D29969
A
B
A
B
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51±43
AVENSIS REPAIR MANUAL (RM1018E)
43. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Using a transmission jack, support the crossmember
sub±assy w/power steering gear assy.
(b) Install the 2 stopper front onto the crossmember sub±
assy.
(c) Install the crossmember sub±assy with the 2 nuts.
Torque: 133 Nm (1,356 kgfcm, 98 ftlbf)
(d) Install the stopper rear onto the crossmember bracket LH.
(e) Install the crossmember bracket LH with the 4 bolts.
Torque:
Bolt A: 133 Nm (1,356 kgfcm, 98 ftlbf)
Bolt B: 80 Nm (816 kgfcm, 59 ftlbf)
(f) Install the stopper rear onto the crossmember bracket
RH.
(g) Install the crossmember bracket RH with the 4 bolts.
Torque:
Bolt A: 133 Nm (1,356 kgfcm, 98 ftlbf)
Bolt B: 80 Nm (816 kgfcm, 59 ftlbf)
(h) Install the engine mounting insulator RR to the cross-
member sub±assy with the bolt and the 3 nuts.
Torque: 52 Nm (530 kgfcm, 38 ftlbf)
(i) Install the center member with the 4 bolts.
Torque:
Bolt A: 45 Nm (459 kgfcm, 33 ftlbf)
Bolt B: 52 Nm (530 kgfcm, 38 ftlbf)
Page 2850 of 5135

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)
Page 2851 of 5135

D30705
LHD:
A
B
RHD:
Matchmarks
Matchmarks
A
B
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±45
AVENSIS REPAIR MANUAL (RM1018E)
50. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
51.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
52. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
53. INSTALL FRONT WHEELS
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
54. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
55. INSTALL STEERING INTERMEDIATE SHAFT ASSYNO.2
(a) Align the matchmarks on the intermediate shaft assy No.2 and the intermediate shaft.
(b) Install the bolt B and tighten the bolt A. Torque: 35 N m (360 kgf cm, 26 ft lbf)
56.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
57. INSTALL CYLINDER HEAD COVER SUB±ASSY
58.ADD POWER STEERING FLUID (See page 51±4)
59.BLEED POWER STEERING FLUID (See page 51±4)
60.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
61. INSPECT FLUID LEAK
62.INSPECT HOOD SUB±ASSY (See page 75±2)
63.ADJUST HOOD SUB±ASSY (See page 75±2)
64.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
65. INSTALL ENGINE UNDER COVER LH
66. INSTALL ENGINE UNDER COVER RH
67.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
Page 2852 of 5135

510DK±02
D29958
LHD:
Pressure Feed
Tube Assy8.0 (82, 71 in.lbf)
Steering Gear Outlet
Return Tube
44.1 (450, 33)
*41 (414, 30)
Steering Intermediate Shaft Assy No.2
35 (360, 26)
Steering Intermediate Shaft
Column Hole Cover
Silencer Sheet
Clip
Steering Gear Outlet Return Tube
Pressure Feed Tube Assy Steering Column Hole
Cover Sub±assy No.1
Cotter Pin
Rack & Pinion Power
Steering Gear Assy
Stopper Rear
80 (816, 59)
80 (816, 59)
133 (1,356, 98)
Front Stabilizer
Link Assy RH
Stopper
Front
133 (1,356, 98)
89 (908, 66)
74 (755, 55)
Front Stabilizer Link Assy LH
Stopper Rear
Crossmember
Bracket LH
80 (816, 59)
133 (1,356, 98)
80 (816, 59)
Nm (kgfcm, ftlbf): Specified torque Non±reusable part
* For use with SST(s)
52 (530, 38)
133 (1,356, 98)
52 (530, 38)
Center Member
74 (755, 55)49 (500, 36)
Front Suspension
Crossmember Sub±assy
Stopper Front
49 (500, 36)
35 (360, 26)
89 (908, 66)
Engine Under Cover LH Engine Under
Cover RH
45 (459, 33)
49 (500, 36)49 (500, 36)
49 (500, 36)
44.1 (450, 33)
*41 (414, 30)
44.1 (450, 33)
*41 (414, 30)
51±34
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
RACK & PINION POWER STEERING GEAR ASSY
COMPONENTS
Page 2853 of 5135
D30602
Tie Rod End Sub±assy RH
Lock NutSteering Rack Boot Clip
Steering Rack Boot No.1
Steering Rack Boot
No.1 Clamp
Lock Nut
Steering Rack
Boot No.2 Clamp
Steering Rack Boot
No.2
Steering Rack Boot Clip
Tie Rod End Sub±assy LH
Non±reusable part
Silicon greaseNm (kgfcm, ftlbf) : Specified torque
74 (750, 54)
74 (750, 54)
± POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51±35
AVENSIS REPAIR MANUAL (RM1018E)
Page 2854 of 5135

510DJ±02
D25320
No.1 Engine HangerNo.2 Engine Hanger
Front:Rear:
51±28
±
POWER STEERING STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
NOTICE:
When installing, coat the parts indicated by the arrows with power steering fluid or molybdenum dis-
ulfide lithium base grease (See page 51±27).
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 51±36)
4. SEPARATE STEERING COLUMN HOLE COVER SUB±ASSY NO.1
5. REMOVE FRONT WHEELS
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE ENGINE UNDER COVER RH
8.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
9. SEPARATE TIE ROD END SUB±ASSY RH SST 09628±62011
HINT:
Perform the same procedure on the other side.
10. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
11.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
12. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.
13.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
14. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
15. REMOVE HOOD SUB±ASSY
16. REMOVE CYLINDER HEAD COVER SUB±ASSY
17. SUSPEND ENGINE ASSEMBLY
(a) Remove the 2 PCV hoses.
(b) Install the 2 engine hangers in the correct direction.No.1 engine hanger: 12281±22021
No.2 engine hanger: 12281±15040
Bolt: 90512±B1016
Torque: 38 N m (387 kgf cm, 28 ft lbf)
(c) Attach the engine chain hoist to the hangers.
CAUTION:
Do not attempt t hang the ingine by hooking the chain to
any other part.
18.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 51±36)
19. REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1
Page 2855 of 5135
F40259
Matchmarks
C80324
F40049
SST(s)
Vinyl Tape
F40050
Matchmarks
± POWER STEERINGSTEERING GEAR ASSY
51±29
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the intermediate shaft and the pin-
ion shaft.
(b) Remove the bolt and the steering intermediate shaft.
21. REMOVE STEERING GEAR ASSY
(a) Remove the 4 bolts, the 4 nuts and the steering gear assy
from the crossmember sub±assy.
NOTICE:
Because the nut has its own stopper, do not turn the nut
and torque the bolt with the nut fixed.
22. FIX STEERING GEAR ASSY
(a) Using SST(s), secure the steering gear assy in a vise.
SST 09612±00012
HINT:
Tape the SST(s) before use.
23. REMOVE TIE ROD END SUB±ASSY LH
(a) Place matchmarks on the tie rod end sub±assy and the
rack end sub±assy.
(b) Loosen the lock nut and remove the tie rod end sub±assy
and the lock nut.
24. REMOVE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
Page 2856 of 5135

ZK8184
F40083
F40052
SST(s)
SST(s)Hold
Turn
F40051
SST(s) 51±30
± POWER STEERINGSTEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
25. INSPECT TIE ROD END SUB±ASSY LH
(a) Secure the tie rod end sub±assy in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torx wrench, turn the nut continuously at a rate of
2 to 4 seconds per turn and take the torque reading on the
5th turn.
Turning torque:
0.29 to 1.96 Nm (3 to 20 kgfcm, 2.57 to 17.35 in.lbf)
26. INSPECT TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side.
27. REMOVE STEERING RACK BOOT CLIP
(a) Using a pliers, remove the 2 boot clips from each rack boots.
28. REMOVE STEERING RACK BOOT NO.2 CLAMP
(a) Using a screwdriver, unstake the rack boot No.2 clamp.
NOTICE:
Be careful not to damage the boot.
29. REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT:
Perform the same procedure on the other side.
30. REMOVE STEERING RACK BOOT NO.2
31. REMOVE STEERING RACK BOOT NO.1
32. REMOVE STEERING RACK END SUB±ASSY
(a) Using SST(s), hold the steering rack steadily and using
another SST(s), remove the rack end sub±assy.
SST 09922±10010
NOTICE:
Use SST(s) 09922±10010 in the direction shown in the il-
lustration.
HINT:
Perform the same procedure on the other side.
33. INSPECT TOTAL PRELOAD
(a) Temporarily install the RH and LH rack end sub±assy.
(b) Using SST(s) and a torque wrench, check the preload.
SST 09616±00011
Preload (turning):
0.6 to 1.1 Nm (6 to 11 kgfcm, 5.3 to 9.7 in.lbf)
If it is not within specification, replace the steering gear assy.