sensor TOYOTA AVENSIS 2002 Repair Manual

190NK±01
A78515
A78516
A77903
(a)
(a)
(b)
(b)
(b)
A77904
(f)
(f)
(e)
(d)
Terminal Cap
19±20
±
STARTING & CHARGING GENERATOR ASSY(1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
GENERATOR ASSY(1AZ±FE/1AZ±FSE)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER LH
(a)Remove the 6 screws and 5 clips, and then remove the engine under cover.
2.REMOVE ENGINE UNDER COVER RH
(a)Remove the 6 screws and the 3 clips, and then remove the engine under cover.
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4. REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
5. REMOVE FAN AND GENERATOR V BELT SST 09249±63010
HINT:

1AZ±FE: 14±105

1AZ±FSE: 14±185
6. REMOVE GENERATOR ASSY
(a) Disconnect the 2 heated oxygen sensor connectors. (1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
(b) Remove the 2 connector clamps of the heated oxygen sensor and the wire harness clamp.
(1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
(c) Remove the terminal cap.
(d) Remove the nut and disconnect the generator wire.
(e) Disconnect the generator connector.
(f) Remove the 2 wire harness clamps.

A77905
A77906
A77905
A
B
± STARTING & CHARGINGGENERATOR ASSY (1AZ±FE/1AZ±FSE)
19±21
AVENSIS REPAIR MANUAL (RM1018E)
(g) Remove the 2 bolts, and then remove the generator.
(h) Remove the bolt, and then remove the wire harness
clamp bracket.
7. INSTALL GENERATOR ASSY
(a) Install the wire harness clamp bracket wire the bolt.
Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
(b) Install the generator the 2 bolts.
Torque:
52 N
m (530 kgf
cm, 38 ft
lbf) for bolt A
21 N
m (214 kgf
cm, 16 ft
lbf) for bolt B
(c) Install the 2 wire harness clamps.
(d) Connect the generator connector.
(e) Install the generator wire with the nut.
Torque: 9.8 N
m (100 kgf
cm, 7 ft
lbf)
(f) Install the terminal cap.
(g) Install the 2 connector clamps of the heated oxygen sen-
sor and the wire harness clamp.
(1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
(h) Connect the 2 heated oxygen sensor connectors.
(1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
8. INSTALL FAN AND GENERATOR V BELT
SST 09249±63010
HINT:

1AZ±FE: 14±105

1AZ±FSE: 14±185
9. INSTALL ENGINE ROOM COVER SIDE
10. INSTALL RADIATOR SUPPORT OPENING COVER
11. INSTALL ENGINE UNDER COVER RH
12. INSTALL ENGINE UNDER COVER LH

5006Z±01
50±20
±
STEERING COLUMN POWER STEERING ECU ASSY
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING ECU ASSY
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.1 (See page 71±11)
4.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
5.REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 71±11)
6.REMOVE STEERING COLUMN COVER LWR (See page 50±9)
7. REMOVE STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY (See page 50±9)
8.REMOVE COMBINATION METER ASSY (See page 71±11)
9.REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (See page 71±11)
10.REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2(See page 71±11)
11.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
12.REMOVE FRONT PILLAR GARNISH LH (See page 71±11)
13.REMOVE FRONT PILLAR GARNISH RH (See page 71±11)
14.DISCONNECT PASSENGER AIRBAG CONNECTOR(See page 71±11)
15. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG
ASSY (See page 71±11)
16. REMOVE POWER STEERING ECU ASSY
NOTICE:
Thoroughly check the procedures for removing and instal-
ling 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 har-ness 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 4 connectors.
(d) LHD: (1) Remove the 2 bolts,screw and power steering ECUassy.
(e) RHD: (1) Remove the 2 bolts,2 screw and power steeringECU assy.

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
Bolt (A)
Bolt (B)
ScrewScrew Bolt (B)Bolt (A)
± STEERING COLUMNPOWER STEERING ECU ASSY
50±21
AVENSIS REPAIR MANUAL (RM1018E)
17. INSTALL POWER STEERING ECU ASSY
(a) LHD:
Install the power steering ECU assy with the 2 bolts and
screw.
Torque:
BOLT (A): 8.0 N
m (82 kgf
cm, 71 in.
lbf)
BOLT (B): 15.5 N
m (158 kgf
cm, 11 ft
lbf)
(b) RHD:
Install the power steering ECU assy with the 2 bolts and
2 screws.
Torque:
BOLT (A): 8.0 N
m (82 kgf
cm, 71 in.
lbf)
BOLT (B): 15.5 N
m (158 kgf
cm, 11 ft
lbf)
(c) Connect the 4 connectors.
(d) Align the marks on the torque sensor wire harness with
the clamp, as shown in the illustration.

50±22
±
STEERING COLUMN POWER STEERING ECU ASSY
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

When reusing the clamp, check that there is no dam-
age on it.

When reinstalling the wire harness, make sure there
is no twist in the harness or with other wire harness.
18. CONNECT BATTERY NEGATIVE TERMINAL
19.INSPECT SRS WARNING LIGHT (See page 05±1184)
20.PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT (See page 05±1045)

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.