TOYOTA AVENSIS 2005 Service Repair Manual

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)

5006X−01
Steering
Column
Protector No.1
F44781
Horn Button Assy
Steering Wheel Assy
Spiral Cable Sub −Assy
Steering Column Cover
Headlamp Dimmer Switch AssySteering Column Assy
Steering
Sliding Yoke
Sub− Assy
Steering Intermediate
Shaft Assy No.2
Column Hole Cover Silencer Sheet
Steering Column Cover LWR
Windshield Wiper
Switch Assy
N

m (kgf
cm, ft
lbf): Specified torque
OIL Pressure Power Steering:
Steering Intermediate
Shaft Assy No.2
Steering
Sliding Yoke
Sub−Assy
35 (360, 26)
Column Hole Cover
Silencer Sheet
LHD Steering Position Type:
LHD Steering Position
Type: w/ Instrument Cluster
Finish Panel Assy
Floor Shift
Parking Lock Cable
Assy (A/T Transaxle)
Instrument Panel
Hole Cover
5 (51, 44 in.




lbf)
18 (184, 13)
18 (184, 13)
Instrument Panel
Airbag Assy
18 (184, 13)
18 (184, 13)
18 (184, 13)
25 (255, 18)
50 (510, 37)
35 (360, 26)
35 (360, 26)
28 (286, 21)
35 (360, 26)
28 (286, 21)
25 (255, 18)
25 (255, 18)
−
STEERING COLUMN STEERING COLUMN ASSY
50−5
STEERING COLUMN ASSY
COMPONENTS

F44782
Transponder Key Amplifier
Tapered±Head Bolt
Steering Column Clamp Upper
Ignition or Starter Switch Assy
Un±lock Warning
Switch Assy
Steering Column Upper W/Switch Bracket Assy Ignition Switch Lock Cylinder Assy
Non±reusable part

Steering Column Assy
50±6
± STEERING COLUMNSTEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)

F44779
Horn Button Assy
Steering Wheel Assy
Headlamp Dimmer Switcn Assy
Spiral Cable
Windshield Wiper Switch Steering Column Cover
Steering Column Assy
Steering
Intermediate
Shaft Assy
No.2
Steering Sliding
Yoke sub−assy
Column Hole Cover Silencer Sheet
N
m (kgf
cm, ft
lbf): Specified torque Steering Sliding
Yoke sub
−assy
Steering Intermediate
Shaft Assy No.2
LHD Steering Position Type:
Electric Power Steering:
35 (360, 26)
35 (360, 26)
35 (360, 26)
Column Hole Cover Silencer Sheet
Steering Column Cover
LW R
Floor Shift Parking Lock
Cable Assy (A/T Transaxle)
Instrument Panel Airbag Assy
18 (184, 13)
Steering
Column
Protector
No.1
Instrument
Panel
Hole Cover
18 (184, 13)
18 (184, 13)
5 (51, 44 in.




lbf)
25 (255, 18)
18 (184, 13)
18 (184, 13)
LHD Steering Position Type: w/ Instrument Cluster
Finish Panel Assy
50 (510, 37)
25 (255, 18)
Steering Column
Protector No.1
35 (360, 26)
M/T Transaxle:25 (255, 18)
−
STEERING COLUMN STEERING COLUMN ASSY
50−7

F44780
Transponder Key Amplifier AssyTapered±head Bolt
Ignition or Starter Switch Assy Steering Column Assy

Non±reusable part
Steering Column Clamp Upper
Un±lock Warning
Switch Assy
Steering Column Upper w/ Switch Bracket Assy Ignition Switch Lock Cylinder Assy
50±8
± STEERING COLUMNSTEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)

5000E±04
F44778
Maximum
Freeplay
30 mm (1.18 in.) 50±4
± STEERING COLUMNSTEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK STEERING WHEEL FREEPLAY
(a) Stop the vehicle and face the tires straight ahead.
(b) Rock the steering wheel gently up and down with a finger
lightly, check the steering wheel freeplay.
Maximum freeplay: 30 mm (1.18 in.)

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