instrument cluster TOYOTA AVENSIS 2005 Service Repair Manual

320G5±02
F45426
F45427
F42642
±
BRAKE STEERING SENSOR
32±65
AVENSIS REPAIR MANUAL (RM1018E)
STEERING SENSOR
REPLACEMENT
1.PRECAUTION (See page 60±1)
2. REMOVE PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
4.REMOVE HORN BUTTON ASSY (See page 60±17)
5.REMOVE STEERING WHEEL ASSY (See page 50±9)
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 STEERING COLUMN ASSY(See page 50±9)
9.REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
10. REMOVE STEERING SENSOR
(a) Place the steering column assy on the V±blocks and rub-ber stick.
(b) Using a extension bar and hammer, remove the steering column bracket spacer and 2 tilt steering support collar
No.1 from the steering column assy.
NOTICE:

During this procedure, do not apply the strong shock
to the steering sensor.

Do not apply any oil or grease on the pin.
(c) Using a screwdriver, remove the bush from the steering column assy.
(d) Disconnect the pick on the steering sensor and steering sensor adapter, then remove the steering sensor from the
column shaft.
(e) Remove the steering sensor adapter.

F42641
F42642
F45427
F45426
32±66
±
BRAKE STEERING SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
11. INSTALL STEERING SENSOR
(a) Install the steering sensor adapter to the column shaft.
HINT:
At that time, the projection of the steering sensor adapter
should be fit in the hole on the steering column shaft.
(b) Install the steering sensor to the column shaft.
HINT:

At that time, the pick of the steering sensor should be fit
to the pick of the steering sensor adapter.

After installation, make sure the steering sensor is fixed
securely in the steering sensor adapter.
(c) Place the steering column assy on the V±blocks and rub- ber stick.
(d) Install the 2 new tilt steering support collar No.1 to the steering column assy.
(e) Using a extension bar and hammer, install the steering column bracket spacer to the steering column assy.
NOTICE:

During this procedure, do not apply the strong shock
to the steering sensor.

Do not apply any grease or oil on the pin.
12.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
13.INSTALL STEERING COLUMN ASSY (See page 50±9)
14.INSTALL SPIRAL CABLE SUB±ASSY (See page 60±26)
15. INSTALL STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY (See page 50±9)
16.INSTALL STEERING COLUMN COVER LWR (See page 50±9)
17.INSTALL STEERING WHEEL ASSY (See page 50±9)
18. INSPECT STEERING WHEEL CENTER POINT
19.INSTALL HORN BUTTON ASSY (See page 60±17)

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.

F44783
MatchmarksSST
F44784
50±10
±
STEERING COLUMN STEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE STEERING WHEEL ASSY
(a) Remove the steering wheel assy set nut.
(b) Place matchmarks on the steering wheel assy and steer- ing main shaft assy.
(c) Using SST, remove the steering wheel assy. SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±05021)
6.REMOVE INSTRUMENT PANEL UNDER COVER SUB±ASSY NO.1 (See page 71±11)
7.REMOVE INSTRUMENT PANEL HOLE COVER (See page 60±54)
8.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
9. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.1 (ELECTRIC POWER STEERING) (See page 71±11)
10. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (ELECTRIC POWER
STEERING) (See page 71±11)
11. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (ELECTRIC POWER STEERING) (See page 71±11)
12. REMOVE STEERING COLUMN COVER LWR
(a) Remove the 3 screws and steering column cover LWR.
13. REMOVE STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Disengage the 2 clips and remove the steering column cover w/instrument cluster finish panel assy.
14.REMOVE COMBINATION METER ASSY (ELECTRIC POWER STEERING) (See page 71±11)
15. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (ELECTRIC POWER STEERING) (See page 71±11)
16. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2 (ELECTRIC POWER STEERING) (See page 71±11)
17. REMOVE GLOVE COMPARTMENT DOOR ASSY (ELECTRIC POWER STEERING)
(See page 71±11)
18.REMOVE FRONT PILLAR GARNISH LH (ELECTRIC POWER STEERING) (See page 71±11)
19.REMOVE FRONT PILLAR GARNISH RH (ELECTRIC POWER STEERING) (See page 71±11)
20. DISCONNECT PASSENGER AIRBAG CONNECTOR (ELECTRIC POWER STEERING) (See page 71±11)
21. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (ELECTRIC POWER STEERING) (See page 71±11)
22.REMOVE HEADLAMP DIMMER SWITCH ASSY (See page 65±27)
23.REMOVE WINDSHIELD WIPER SWITCH ASSY (See page 66±24)
24.REMOVE SPIRAL CABLE SUB±ASSY (See page 60±26)

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

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

550YU±01
I37428
I352826 Claws
I352864 Claws
55±50
±
HEATER & AIR CONDITIONER AIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±48
1.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
2.REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
4.REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (See page 67±5)
5.REMOVE RADIO BRACKET NO.1 (See page 67±5)
6.REMOVE RADIO BRACKET NO.2 (See page 67±5) 7. REMOVE AIR CONDITIONING CONTROL ASSY
(a) Remove the air conditioning control assy as shown in theillustration.
8. REMOVE AIR CONDITIONING PANEL SUB±ASSY
(a) Remove the 4 screws.
(b) Manual A/C: Release the 6 claw fittings and disconnect the air condi-
tioning panel sub±assy.
(c) Auto A/C: Release the 4 claw fittings and disconnect the air condi-
tioning panel sub±assy.

6009S±04
H42634
H42636 Claw
60±26
±
SUPPLEMENTAL RESTRAINT SYSTEM SPIRAL CABLE SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
SPIRAL CABLE SUB±ASSY
REPLACEMENT
HINT:
COMPONENTS: See page 60±16
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4.REMOVE HORN BUTTON ASSY (See page 60±17)
5.REMOVE STEERING WHEEL ASSY (See page 50±9) SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±\
05021)
6.REMOVE INSTRUMENT PANEL HOLE COVER (See page 60±54)
7.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
8. REMOVE STEERING COLUMN COVER SUB±ASSYLOWER
(a) Remove the 3 screws and the steering column cover sub± assy lower.
9. REMOVE STEERING COLUMN COVER
W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Remove the steering column cover w/instrument cluster finish panel assy.
10. REMOVE SPIRAL CABLE SUB±ASSY
(a) Disconnect the airbag connector and the connector from the spiral cable sub±assy.
(b) Disengage the 3 claws and remove the spiral cable sub±
assy.
11.INSPECT SPIRAL CABLE SUB±ASSY (See page 60±11)
(a) If the following condition is identified, replace the spiral cable sub±\
assy with a new one. Condition:
Scratches or cracks on the connector
Cracks, dents or chips in the spiral cable sub±assy
12. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
(a) Check that the front wheels are facing straight ahead.

6009O±06
H42639N
m (kgf
cm, ft
lbf): Specified torqueTorx Screw
Steering Column Cover
w/Instrument Cluster Fin-
ish Panel Assy
Torx Screw
Horn Button Assy Steering Column Cover AssySpiral Cable Sub±Assy
Steering Wheel Assy
50 (510, 37)
Instrument Panel Airbag Assy
Instrument Panel Hole Cover
8.8 (90, 78 in.
lbf)8.8 (90, 78 in.
lbf)
60±16
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
STEERING WHEEL ASSY
COMPONENTS

670S7±01
I351712 Claws
I35172
I35173
I35175
67±6
±
AUDIO & VISUAL SYSTEM MULTI±DISPLAY (CRT DISPLAY) DISPLAY
AVENSIS REPAIR MANUAL (RM1018E)
MULTI±DISPLAY (CRT DISPLAY) DISPLAY
REPLACEMENT
1.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11) 2. REMOVE INSTRUMENT PANEL REGISTER ASSYCTR
(a) Remove the 2 screws.
(b) Disengage the 2 claws and remove the instrument panel register assy CTR.
(c) Disconnect the connectors.
3. REMOVE DOOR CONTROL SWITCH
(a) Remove the 2 screws and separate the door control switch.
4. REMOVE DOOR CONTROL SWITCH ASSY
(a) Remove the 2 screws and separate the door control switch assy (TILT).
5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Make the multi±display upright.