Page 2874 of 5135
D31004
Inscribed Mark
R08702
Vernier Calipers
F08480
SST(s)
Oil Seal
D30334
Vinyl Tape
± POWER STEERINGVANE PUMP ASSY (AZ Series)
51±13
AVENSIS REPAIR MANUAL (RM1018E)
If necessary, replace the flow control valve assy with the one
having the same letter as inscribed on the housing sub±assy
front.
Inscribed mark: A, B, C, D, E or F
HINT:
There are 6 different marks for flow control valve assy.
MarkPart number
A44330±05130
B44330±05140
C44330±05150
D44330±05160
E44330±05170
F44330±05180
21. INSPECT FLOW CONTROL VALVE COMPRESSION
SPRING
(a) Using vernier calipers, measure the free length of the
compression spring.
Minimum free length: 36.9 mm ( 1.453 in.)
If it is less than the minimum, replace the compression spring.
22. INSPECT PRESSURE PORT UNION SUB±ASSY
(a) If the union seat in the pressure port union sub±assy is remarkably damaged, it may cause fluid leak-
age. Replace the pressure port union sub±assy.
23. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new housing oil seal lip with power steering fluid.
(b) Using SST(s) and a press, install a new housing oil seal.
SST 09950±60010 (09951±00280), 09950±70010
(09951±07100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
24. INSTALL W/PULLEY SHAFT SUB±ASSY
(a) Coat inside bushing surface of the housing sub±assy
front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub±assy.
NOTICE:
Do not damage the oil seal lip.
HINT:
Tape the shaft before inserting.
Page 2876 of 5135
D30335
Inward
Outward
D30336
C70126
C53369
Service Bolt
± POWER STEERINGVANE PUMP ASSY (AZ Series)
51±15
AVENSIS REPAIR MANUAL (RM1018E)
(b) Coat 10 vane pump plates with power steering fluid.
(c) Install the vane pump plates with the round end facing
outward.
28. INSTALL VANE PUMP SHAFT SNAP RING
(a) Using a screwdriver and a snap ring expander, install a
new snap ring to the w/pulley shaft sub±assy.
29. INSTALL VANE PUMP HOUSING SUB±ASSY REAR
(a) Coat a new O±ring with power steering fluid and install it
onto the housing sub±assy rear.
(b) Align the straight pin of the housing sub±assy rear with
the dents of the cam ring, side plate front and housing
sub±assy front, and install the vane pump housing sub±
assy rear with the 4 bolts.
Torque: 22 Nm (224 kgfcm, 16 ftlbf)
30. INSPECT PRELOAD
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Temporarily install the service bolt.
Recommended service bolt:
Thread diameter: 10 mm (0.39 in.)
Thread pitch: 1.25 mm (0.0492 in.)
Bolt length: 50 mm (1.97 in.)
(c) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.27 Nm (2.8 kgfcm, 2.4 ftlbf) or less
If the rotating torque is not as specified, check the housing oil
seal.
31. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Coat a new O±ring with power steering fluid and install it to the oil pressure switch.
(b) Install the oil pressure switch onto the vane pump assy.
Torque: 21 Nm (214 kgfcm, 15 ftlbf)
Page 2877 of 5135
F42475
F40330
A
SST(s)
BFulcrum Length
F41596
Pressure Feed
Tube Assy
Stopper
51±16
± POWER STEERINGVANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
32. INSTALL FLOW CONTROL VALVE ASSY
(a) Coat the compression spring and the flow control valve
assy with power steering fluid.
(b) Install the compression spring and the flow control valve
assy.
(c) Coat a new O±ring with power steering fluid and install it
onto the pressure port union sub±assy.
(d) Install the pressure port union sub±assy.
Torque: 69 Nm (704 kgfcm, 51 ftlbf)
33. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O±ring with power steering fluid, and install it to the suction port union.
(b) Install the suction port union with the bolt.
Torque: 12 Nm (122 kgfcm, 9 ftlbf)
34. INSTALL PUMP BRACKET REAR
(a) Install the vane pump bracket rear with the bolt.
Torque: 44 Nm (449 kgfcm, 32 ftlbf)
HINT:
Make sure that the stopper of the bracket touches the vane pump body, then torque the bolt.
35. INSTALL VANE PUMP ASSY
(a) Temporarily tighten the bolt A to the vane pump assy.
(b) Install the vane pump assy and the bolt B.
Torque: 37 Nm (377 kgfcm, 27 ftlbf)
(c) Using SST(s) and a deep socket (14 mm), tighten the bolt
A.
SST 09249±63010
Torque: 26 Nm (264 kgfcm, 19 ftlbf)
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.
(d) Connect the connector to the oil pressure switch.
36. CONNECT PRESSURE FEED TUBE ASSY
(a) Install the pressure feed tube assy and gasket to the vane
pump assy with the union bolt.
HINT:
Make sure the stopper of the pressure feed tube assy touches
the pump housing front as shown in the illustration.
(b) Using a spanner (27 mm) to hold the pressure port union,
torque the union bolt.
Torque: 52 Nm (525 kgfcm, 38 ftlbf)
(c) Install the pressure feed tube assy with bolt to the pump
bracket rear.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
Page 2878 of 5135
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±17
AVENSIS REPAIR MANUAL (RM1018E)
37. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No.1 with the clip.
NOTICE:
Take care not to spill fluid on the V belt.
38. INSTALL FAN AND GENERATOR V BELT
1AZ±FE: (See page 14±105)
1AZ±FSE: (See page 14±185)
39. INSTALL ENGINE UNDER COVER RH
40. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
41.ADD POWER STEERING FLUID (See page 51±4)
42.BLEED POWER STEERING FLUID (See page 51±4)
43.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
44. INSPECT FLUID LEAK
Page 2879 of 5135
510DF±02
F42473
Power Steering
Suction Port Union
O±ring
w/pulley Shaft Sub±assy
Vane Pump Side
Plate Front
Vane Pump Cam Ring10
Nm (kgfcm, ftlbf) : Specified torque
Non±reusable part
Power steering fluid
Pump Bracket Rear
Flow Control Valve Assy
Flow Control Valve
Compression Spring
44 (449, 32)
Vane Pump Housing
Sub±assy RearVane Pump Housing
Sub±assy Front
Vane Pump Rotor
Vane Pump Plate
22 (224, 16)
Vane Pump Housing
Oil Seal
Power Steering
Oil Pressure Switch
21 (214, 15)
69 (704, 51)
Vane Pump
Shaft Snap Ring O±ring
O±ring
O±ring
22 (224, 16)
Pressure Port Union
Sub±assy
12 (122, 9)
51±8
± POWER STEERINGVANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
VANE PUMP ASSY (AZ Series)
COMPONENTS
Page 2880 of 5135
510DE±02
F40449
R11229
Normal
Abnormal
R00427
51±4
± POWER STEERINGPOWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords,
etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
missing chunks from the ribs are found on the belt, it should be
replaced.
2. BLEED POWER STEERING SYSTEM
(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with the
stands.
(c) Turn the steering wheel.
(1) With the engine stopped, turn the wheel slowly from
lock to lock several times.
(d) Lower the vehicle.
(e) Start the engine.
(1) Run the engine at idle for a few minutes.
(f) Turn the steering wheel.
(1) With the engine idling, turn the wheel to right full lock
position and keep it there for 2 to 3 seconds, then
turn the wheel to left full lock position and keep it
there for 2 to 3 seconds.
(2) Repeat (1) several times.
(g) Stop the engine.
(h) Check for foaming or emulsification.
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
(i) Recheck the fluid level.
3. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON II or III
HINT:
If the fluidis hot, check that the fluid level is within the HOT LEV-
EL range on the oil reservoir. If the fluid is cold, check that it is
within the COLD LEVEL range.
Page 2881 of 5135
R11229
NormalAbnormal
R11786Engine Idling Engine Stopped5 mm (0.20 in.)
or less
±
POWER STEERING POWER STEERING SYSTEM
51±5
AVENSIS REPAIR MANUAL (RM1018E)
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 C (176 F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed the power steering
system.
(f) With the engine idling, measure the fluid level in the oil reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(i) Check the fluid level.
4. CHECK STEERING FLUID PRESSURE
(a) AZ Series: Disconnect the pressure feed tube assy from the vane
pump assy (See page 51±9).
(b) 1CD±FTV: Disconnect the pressure feed tube assy from the vane
pump assy (See page 51±19).
(c) AZ Series: Connect SST(s), as shown in the illustration on the next
page.
SST 09640±10010 (09641±01010, 09641±01030, 09641±01060)
NOTICE:
Check that the valve of SST(s) is in the open position.
(d) 1CD±FTV: Connect SST(s), as shown in the illustration on the next
page.
SST 09640±10010 (09641±01010, 09641±01020, 09641±01030)
NOTICE:
Check that the valve of SST(s) is in the open position.
(e) Bleed the power steering system.
(f) Start the engine and run it at idle.
(g) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 C (176 F)
Page 2882 of 5135
D30364
Attachment
OUT
IN IN OUTAttachment
SST(s) SST(s)
Attachment
Attachment AZ Series:
1CD±FTV:
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST(s) Closed
Z15499
Oil
Reservoir
PS Vane
Pump PS Gear
SST(s) Open 51±6
± POWER STEERINGPOWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(h) With the engine idling, close the valve of SST(s) and ob-
serve the reading on SST(s).
Minimum fluid pressure:
AZ Series:
8,300 to 9,000 kPa (85 to 92 kgf/cm
2, 1,204 to 1,305 psi)
1CD±FTV:
8,800 to 9,500 kPa (90 to 97 kgf/cm
2, 1,276 to 1,378 psi)
NOTICE:
Do not keep the valve closed for more than 10 se-
conds.
Do not let the fluid temperature become too high.
(i) With the engine idling, open the valve fully.
(j) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Fluid pressure difference:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
