TOYOTA AVENSIS 2002 Repair Manual

F44857F44857
LHD:RHD:
Torque Sensor Wire Harness Clamp
Marks
Power Steering ECU Assy
Front
Motor Wire Harness
Torque Sensor
Wire Harness
Front
Torque Sensor
Wire Harness
Motor Wire Harness
Power Steering ECU Assy
Torque Sensor Wire Harness Clamp
Marks 50±12
± STEERING COLUMNSTEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
28. DISCONNECT POWER STEERING ECU ASSY (ELECTRIC POWER STEERING)
NOTICE:
Thoroughly check the procedures for removing and installing the power steering ECU assy when
replacing it. Do the same for the removing and installing the steering column assy.
(a) Mark the clamp position on the torque sensor wire harness in order to reinstall the wire harness as
shown in the illustration.
(b) Disconnect the torque sensor wire harness from the clamp.
NOTICE:
In case the clamp will be reused, pay attention so as not to damage it.
(c) Disconnect the 2 connectors.
29. REMOVE STEERING COLUMN ASSY
(a) Disconnect the wire harness and wire harness clamps.
(b) Loosen the 3 steering column assy set bolts.

F44789
RHD:
A
B
Matchmarks
F44790
LHD:
Matchmarks
BA
F45269
F44793Matchmarks
±
STEERING COLUMN STEERING COLUMN ASSY
50±13
AVENSIS REPAIR MANUAL (RM1018E)
(c) RHD:
Place matchmarks on the intermediate shaft assy No. 2
and steering intermediate shaft.
(d) RHD: Loosen the bolt A and remove the bolt B, then disconnect
the intermediate shaft assy No.2.
(e) LHD: Place matchmarks on the steering sliding yoke sub±assy
and steering intermediate shaft.
(f) LHD: Loosen the bolt A and remove the bolt B, then disconnect
the steering sliding yoke sub±assy.
(g) RHD, M/T: Remove the bolt and protector.
(h) Remove the 3 bolts and steering column assembly.
30. REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (RHD STEERING POSITION TYPE)
(a) Remove the bolt A and steering intermediate shaft assy No. 2.
31. REMOVE STEERING SLIDING YOKE SUB±ASSY (LHD STEERING POSITION TYPE)
(a) Remove the bolt A and steering sliding yoke sub±assy. 32. REMOVE STEERING SLIDING YOKE SUB±ASSY(RHD STEERING POSITION TYPE)
(a) Place matchmarks on the steering sliding yoke sub±assy
and steering main shaft.
(b) Remove the bolt and steering sliding yoke sub±assy.
(c) W/VSC: Remove the steering sensor (See page 32±65).

F44793Matchmarks
F44794
Screw
Extractor
F44795
SST
F44796
F44797
50±14
±
STEERING COLUMN STEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
33. REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (LHD STEERING POSITION TYPE)
(a) Place matchmarks on the steering intermediate shaft
assy No. 2 and steering main shaft.
(b) Remove the bolt and steering intermediate shaft assy No. 2.
(c) W/VSC:
Remove the steering sensor (See page 32±65).
34. REMOVE STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
(a) Using a centering punch, mark the center of the 2 ta- pered±head bolts.
(b) Using a 3 ± 4 mm (0.12 ± 0.16 in.)drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts and steering column upper with switch bracket assy.
NOTICE:
Do not give the strong force to the motor part.
35. INSPECT STEERING COLUMN ASSY (ELECTRIC POWER STEERING)
(a) Using SST and a torque wrench, check the rotating torque.
SST 09616±00011
Rotating torque (1 turn for 2 sec.):
0.4 ± 1.1 N
m (4 ± 11 kgf
cm, 3.5 ± 9.5 in.
lbf)
36. REMOVE TRANSPONDER KEY AMPLIFIER
(a) Widen the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver.
(b) Pull the transponder key amplifier toward the rear of the
vehicle with the claw open.
NOTICE:
Take care not to use excessive force to prevent the case
from being damaged.
37. REMOVE IGNITION SWITCH LOCK CYLINDER ASSY
(a) Place the ignition switch lock cylinder assy at the ACC position.
(b) Push down the stop pin with a screwdriver, and pull out the cylinder assy.

F44798
F44799
F44793Matchmarks
±
STEERING COLUMN STEERING COLUMN ASSY
50±15
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE UN±LOCK WARNING SWITCH ASSY
(a) Slide the unlock warning switch assy out of the steering column upper br\
acket.
39. REMOVE IGNITION OR STARTER SWITCH ASSY
(a) Remove the 2 screws and ignition or starter switch assy.
40. INSTALL IGNITION OR STARTER SWITCH ASSY
(a) Install the ignition or starter switch assy to the steering column upper w/swit\
ch bracket assy with the
2 screws.
41. INSTALL UN±LOCK WARNING SWITCH ASSY
(a) Install the un±lock warning switch assy.
(b) Connect the un±lock warning switch assy connector to the ignition or \
starter switch assy.
42. INSTALL IGNITION SWITCH LOCK CYLINDER ASSY
(a) Make sure of the ignition switch lock cylinder assy at the ACC position.\
(b) Install the ignition switch lock cylinder assy.
43. INSPECT STEERING LOCK OPERATION
(a) Check that the steering lock mechanism is activated when removing the ke\
y.
(b) Check that the steering lock mechanism is deactivated when inserting the\
key and turning it to ACC position.
44. INSTALL TRANSPONDER KEY AMPLIFIER
(a) Align the transponder key amplifier with the installationposition of the upper bracket with the amplifier inclined.
(b) Push the transponder key amplifier up and connect it to the upper bracket.
NOTICE:
Take care not to push the amplifier up with excessive force
to prevent it from being damaged.
45. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
(a) Temporarily install the steering column upper with switch bracket assy and steering column upper clamp with 2 new
tapered±head bolts.
(b) Tighten the 2 tapared±head bolts until the bolt heads break off.
46. INSTALL STEERING SLIDING YOKE SUB±ASSY (RHD STEERING POSITION TYPE)
(a) W/VSC:
Install the steering sensor (See page 32±65).
(b) Align matchmarks on the steering sliding yoke and steer- ing main shaft.
(c) Oil Pressure Power Steering
(1) Install the steering sliding yoke with the bolt.
Torque: 28 N
m (286 kgf
cm, 21 ft
lbf)

F44793Matchmarks
F44789
RHD:
Matchmarks
A
B
F45709
50−16
−
STEERING COLUMN STEERING COLUMN ASSY
(d) Electric Pressure Power Steering
(1) Install the steering sliding yoke with the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
47. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (LHD STEERING POSITION TYPE)
(a) W/VSC:
Install the steering sensor (See page 32− 65).
(b) Align matchmarks on the steering intermediate shaft assy
No. 2 and steering main shaft.
(c) Oil Pressure Power Steering (1) Install the steering intermediate shaft assy No. 2
with the bolt.
Torque: 28 N
m (286 kgf
cm, 21 ft
lbf)
(d) Electric Pressure Power Steering (1) Install the steering intermediate shaft assy No. 2
with the bolt.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
48. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (RHD STEERING POSITION TYPE)
(a) Temporarily install the steering intermediate shaft assy No. 2 with the bolt A.
49. INSTALL STEERING SLIDING YOKE SUB −ASSY (LHD STEERING POSITION TYPE)
(a) Temporarily install the steering sliding yoke with the bolt A.
50. INSTALL STEERING COLUMN ASSY
(a) Install the steering column assembly with the 3 bolts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(b) RHD: Align the matchmarks on the intermediate shaft assy No.
2 and steering intermediate shaft.
(c) RHD: Install the bolt B and tighten the bolt A.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
HINT:
When replacing the intermediate shaft assy No. 2 with a new
one, set the front tires in the straight ahead position and make
the bolt hole for the intermediate shaft assy No. 2 and extension
face straight rearward as illustrated, and install the bolt.

F44790
LHD:
Matchmarks
BA
C82037
F45269
−
STEERING COLUMN STEERING COLUMN ASSY
50−17
(d) LHD:
Align matchmarks on the sliding yoke and steering inter-
mediate shaft.
(e) LHD:
Install the bolt B and tighten the bolt A.
Torque: 35 N
m (360 kgf
cm, 26 ft
lbf)
HINT:
When replacing the sliding yoke with a new one, set the front
tires in the straight ahead position and make the bolt hole for the
yoke and extension face straight rearward as illustrated, and
install the bolt.
(f) RHD, M/T: Install the protector with the bolt.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
51. INSTALL FLOOR SHIFT PARKING LOCK CABLE ASSY (A/T TRANSAXLE)(See page 40 −74)

F44857F44857
LHD:RHD:
Torque Sensor Wire Harness Clamp
Marks
Power Steering ECU Assy
Front
Motor Wire Harness
Torque Sensor
Wire Harness
Front
Torque Sensor
Wire Harness
Motor Wire Harness
Power Steering ECU Assy
Torque Sensor Wire Harness Clamp
Marks
F44786
50±18
± STEERING COLUMNSTEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
52. CONNECT POWER STEERING ECU ASSY (ELECTRIC POWER STEERING)
(a) Connect the 2 connectors.
(b) Align the marks on the torque sensor wire harness with the clamp, as shown in the illustration.
NOTICE:

When reusing the clamp, check that there is no damage on it.

When reinstalling the wire harness, make sure there is no twist in the harness or with other wire
harness.
53. INSTALL STEERING COLUMN PROTECTOR NO.1
(a) Install the steering column protector with the 2 bolts.
Torque: 5 N
m (51 kgf
cm, 44 ft
lbf)
(b) Connect the wire harness clamp to the steering colum
protector No.1.

F44800
Marks
F44801
Torx ScrewScrew Case
±
STEERING COLUMN STEERING COLUMN ASSY
50±19
AVENSIS REPAIR MANUAL (RM1018E)
54.INSTALL INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
55. INSTALL COLUMN HOLE COVER SILENCER SHEET
56. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
57.INSTALL SPIRAL CABLE SUB±ASSY (See page 60±26)
58. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise by hand until it becomesharder to turn.
(c) Then rotate the cable clockwise about 2.5 turns to align the marks.
HINT:
The cable will rotate about 2.5 turns to either left or right of the
center.
59. INSTALL STEERING WHEEL ASSY
(a) Align matchmarks on the steering wheel and main shaft assembly.
(b) Install the steering wheel set nut. Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
(c) Connect the connector.
60. INSTALL HORN BUTTON ASSY
NOTICE:

Never use airbag parts from another vehicle. When
replacing parts, replace with new ones.

Make sure the horn button assy is installed with the
specified torque.

If the horn button assy has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the horn button assy with a new one.

When installing the horn button assy, take care that
the wirings do not interfere with other parts and that
they are not pinched between other parts.
(a) Connect the terminal.
(b) Connect the airbag connector.
(c) Install the steering horn button assy after confirming that the circumference groove of the torx screws is caught on
the screw case.
(d) Using a torx socket wrench, torque the 2 screws. Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
61. STEERING WHEEL CENTER POINT
62. CONNECT BATTERY NEGATIVE TERMINAL
63.INSPECT SRS WARNING LIGHT(See page 05±1184)
64. PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT (ELECTRIC POWER STEERING) (See page 05±1045)

5000C±14
±
STEERING COLUMN STEERING SYSTEM
50±1
AVENSIS REPAIR MANUAL (RM1018E)
STEERING SYSTEM
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Be careful to replace the parts properly because they could affect the performance of the steering sys-
tem and result in a driving hazard.
2. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as \
the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence \
could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious acc\
ident. Before servicing (in-
cluding removal or installation of parts, inspection or replacement), be sure \
to read the precautionary
notices in the supplemental restraint system (See page 60±1).
3. HANDLING PRECAUTIONS ON STEERING COLUMN
(a) Do not give an impact to the steering column assy, especially the motor and the torque sensor. If a great impact is given (dropping it to the floor, etc.), replace it with a new one.
(b) When removing the steering column assy, do not pull the harness.
(c) When having replaced the steering column assy and/or the ECU, calibrate the \
zero point of the steer- ing torque sensor.
(d) In the case of disconnecting a connector related to the power steering sys\
tem, turn the ignition switch ON, set the steering wheel in the straight±ahead position and turn th\
e ignition switch OFF before dis-
connecting the connector.
(e) In the case of connecting a connector related to the power steering system, make sure that the ignit\
ion switch is OFF at first. After connecting the connector, set the steering wheel assy in the straight±ahead
position, and then turn the ignition switch ON.
NOTICE:
Never turn on the ignition switch when the steering wheel assy is set in orde\
r than the straight±ahead
position.
(f) If the above operation is not done, the zero point of the steering torque \
sensor is shifted away from the proper position, making difference in the steering effort between right and left. If this happens, per-
form the zero point calibration of the steering torque sensor (See page 05±1042).

5000D±14
50±2
±
STEERING COLUMN STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help you find the cause of the problem. The numbers \
indicate the likelihood of the
cause in the descending order. Check each part in the order shown. Repair or replace these parts as n\
eces-
sary.
Oil pressure power steering:
SymptomSuspect AreaSee page
Hard steering
11. Tires (Improperly inflated)
12.Power steering fluid level (Low)
13.Drive belt (Loose)
14.Front wheel alignment (Incorrect)
15.Steering system joints (Worn)
16.Suspension arm ball joints (Worn)
17.Steering column (Binding)
18.Power steering vane pump
19.Power steering gear28±1
51±4
51±4
26±6 ±
26±24 ±
51±9
51±19
51±36
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gear28±1
26±6 ±
51±36
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear±
26±24 ±
30±22
51±36
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering vane pump
4. Power steering gear51±4 ±
51±9
51±19
51±36