Page 2857 of 5135

F40053
SST(s)
SST(s)
Fulcrum
Length
Hold
Turn
C57755
F400843 mm (0.12 in.) or lessSST(s)
± POWER STEERINGSTEERING 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 Nm (616 kgfcm, 45 ftlbf)
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 shown
in 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.
Page 2858 of 5135

D30584
SST(s)
F40050
Matchmarks
C80324
F40259
Matchmarks
51±32
±
POWER STEERING STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
39. INSTALL STEERING RACK BOOT CLIP
(a) Using a pliers, install the 2 rack boot clips to each rack boots.
(b) Using SST(s), check that the rack boot No.2 is strechy. SST 09616±00011
40. INSTALL TIE ROD END SUB±ASSY LH
(a) Screw the lock nut and the tie rod end sub±assy to the rack end sub±assy until the matchmarks are aligned.
Torque: 74 N m (750 kgf cm, 54 ft lbf)
HINT:
After adjusting toe±in, torque the lock nut
(See page 26±6).
41. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure on the other side. 42. INSTALL STEERING GEAR ASSY
(a) Install the steering gear assy onto the crossmember sub±assy with the 4 bolts and the nuts.
Torque: 49 N m (500 kgf cm, 36 ft lbf)
NOTICE:
Because the nut has its own stopper, do not turn the nut
and torque the bolt with the nut fixed.
43. INSTALL STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the steering intermediate shaft and the steering pinion shaft.
(b) Install the bolt. Torque: 35 N m (360 kgf cm, 26 ft lbf)
44. INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1
45.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 51±36)
Page 2859 of 5135

±
POWER STEERING STEERING GEAR ASSY
51±33
AVENSIS REPAIR MANUAL (RM1018E)
46.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
47. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
48.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
49. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure on the other side.
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 ASSY NO.2 (See page 51±36)
56.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
57. INSTALL CYLINDER HEAD COVER SUB±ASSY
58.INSPECT HOOD SUB±ASSY (See page 75±2)
59.ADJUST HOOD SUB±ASSY (See page 75±2)
60.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
61. INSTALL ENGINE UNDER COVER LH
62. INSTALL ENGINE UNDER COVER RH
63.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
Page 2860 of 5135

510DI±02
D30014
Stopper
Front
133 (1,356, 98)
89 (908, 66)
Front Stabilizer
Link Assy RH
74 (755, 55)
133 (1,356, 98)
80 (816, 59)
Stopper Rear
80 (816, 59)
52 (530, 38)
45 (459, 33)Center Member
52 (530, 38)
133 (1,356, 98)
Stopper Front
89 (908, 66)
80 (816, 59)
133 (1,356, 98)
80 (816, 59)
Stopper Rear
Crossmember
Bracket LH
74 (755, 55)
Front Stabilizer Link Assy LH
Front Suspension
Crossmember Sub±assy
Clip
Steering Intermediate Shaft
Assy No.2
35 (360, 26)
Steering Intermediate Shaft
Steering Column Hole
Cover Sub±assy No.1
Tie Rod End
Sub±assy RH
49 (500, 36)
74 (750, 54)
Lock Nut
Steering Rack
Boot Clip
Steering Rack
Boot No.1
49 (500, 36)
Steering Rack Boot
No.1 Clamp
Steering Rack
End Sub±assy
Lock Nut
Steering Rack Boot
No.2 Clamp
Steering Rack
Boot No.2
Steering Rack
Boot Clip
Tie Rod End
Sub±assy LH
49 (500, 36)
Cotter Pin
Nm (kgfcm, ftlbf) : Specified torque Non±reusable part
Slicon grease
Engine Under Cover LH
Column Hole Cover
Silencer Sheet
Molybdenum disulfide lithium base grease
49 (500, 36)
49 (500, 36)
* For use with SST(s)
83.5 (851, 62)
*60 (616, 45)
74 (750, 54)
± POWER STEERINGSTEERING GEAR ASSY
51±27
AVENSIS REPAIR MANUAL (RM1018E)
STEERING GEAR ASSY
COMPONENTS
Page 2861 of 5135

510DH±02
D30579SST(s)
D30580
C84636
SST(s)
±
POWER STEERING VANE PUMP ASSY (1CD±FTV)
51±19
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
NOTICE:
When using a vise, do not overtighten.
When installing, coat the parts indicated by the arrows with power steer\
ing fluid
(See page 51±18).
1. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
2. REMOVE ENGINE COVER NO.1
(a) Remove the bolt, 4 nuts and the engine cover No. 1.
3. 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.
4. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Remove the bolt and sepatate the tube clamp.
(b) Using SST(s), disconnect the pressure feed tube assyfrom the vane pump assy.
SST 09023±12700
5. REMOVE VANE PUMP ASSY
(a) Remove the 4 bolts, the vane pump assy and the vane pump bracket rear.
6. FIX VANE PUMP ASSY
(a) Using SST(s), hold the vane pump assy in a vise. SST 09630±00014 (09631±00132)
7. 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.
Page 2862 of 5135
D30361
C84483
C57767
C65368
51±20
± POWER STEERINGVANE PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
8. 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.
9. 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.
10. 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.
11. REMOVE VANE PUMP ROTOR
(a) Remove the 10 vane pump plates.
(b) Remove the vane pump rotor.
12. REMOVE VANE PUMP CAM RING
13. 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.
Page 2863 of 5135
C65369
D30331
Cloth
F09875
D30332
LengthThickness
R10282
Feeler Gauge
± POWER STEERINGVANE 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.)
Page 2864 of 5135

D30362Inscribed Mark
D30363
F41622
Compressed Air 51±22
± POWER STEERINGVANE 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 kgfcm
2, 57 to 71 psi) into the opposite side hole,
and confirm that air does not come out from the end holes.