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Starting Problems On Avensis? Solution.


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#1 Rvall

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Posted 02 November 2005 - 11:08 AM

This is a short workshop for changing the ignition switch on an Avensis 2.0 1999.

I've had problems with starting the engine since beginning of summer. The symptoms were like this;
when turning the key to the START position, nothing happens. You have to, either turn it from ON to START a few times or wiggle the key while holding it in the START position, to get connection in the lock to start the motor. :ffs: :help:

This is due to a faulty switch behind the locking barrel, that has been worn down so it does not alway connect. This has nothing to do with the imobilizer system or coding of keys, it is only a mechanical problem and will not be solved by re-coding the keys or such.

:eek:
Be ware, the dealer gave me the wrong part on my first order;
I described the symptoms and where the part is located and they knew exactly what I needed, after a long search in their computer they came up with the part I nedded. It was not in stock so they ordered it.
What I got was a part called something like Coding Unit/Computer Unit remote control (PN 89780-05011).
It's a part in black plastic casing with the front ring around the keyhole (with the text ACC/ON/START) and a short cable with a connector. This is the receiver of the coded keys and it is the wrong part, also it's more expensive and doesn't solve this problem.

When I called them on the phone and described the symptoms again and told them I've got the wrong part, they looked again and came back to me saying that it was the correct part I've got. :angry:
After a little convincing that I had a mechanical problem and not a computer problem, he discussed with another guy and finally they found the correct part.
:eek:

I've had a lot of help from member GnzYza in 'Problems with starting', where you can read how it all started.
Once again, thank GnzYza. :D

1. First you need to get the new part from a Toyota dealer.
The part you need is the SWITCH ASSY, partnumber 84450-02010 (at least for my Avensis -99, but it gives you something to start with at Toyota).

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2. Disassembling.
You'll need a cross/pozidrive screwdrive of medium size, that's all you need.
(It might come in handy with some kind of light because it's rather dark behind the dashboard)

First remove the dash casing below the steering wheel, there are 2 black screws, one to the left...
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...and one to the right and also the golden screw under the cowling.
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Turn the steering wheel so you'll see the last 2 screws behing the wheel...
to the left...
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...and to the right.
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3. Carefully pull the dash casing a bit outwards in the bottom and slide it down to remove it. There are 3 things stuck to this part; the wire for the front hood, an airtube and a wire with connector on it. These can remain in place, just put the casing on the floor.

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4. Separate the top and bottom parts of the cowling, there are only small plastic lockers holding them together now, so a little bending with a screwdriver in the joint between them would do it. The joint is on both the left and the right side, you'll see it clearly if you look close.
The top one could needs not to be removed, but the bottom one does. It might be easier if you loosen the locking handle for adjusting the height of the stearing wheel.

5. Now you should have access to everything under the cowling. Don't be alarmed, it is not so much you have to care about, it is just very much cabling in a very tight space.

Locate the rear of the ignition barrel, where you'll find following parts attached to it:
Posted Image

A and B are just connectors placed on the Switch Assy, remove them, but don't disconnect them.
C is the connector on the Switch Assy. Disconnect it and fold it away.
D is the actual Switch Assy. The arrow points to one of the two screws that holds it in place. (The easy one...)

6. Change the Switch Assy
Remove the two screws that holds the Switch Assy to the rear of the barrel. One is easy to get at, but the other one is rather tricky to access.
The screws might fall off so don't loose them!

Once they are removed, pull the case of the Switch Assy away from the barrel. You can't pull it off all the way, so you'll have to turn it 45 degrees and try to get it out sideways. There are no loose parts there so you are rather free to remove it any way you can. Just keep in mind how you did it since you have to get the new part in, the same way.

7. Assembling.
Place the screw that was hard to get at, in it's hole on the new Switch Assy before placing it in position. It is very hard to get it in place through all cables.
Now, just tighten the screws for the Switch Assy, re-connect the cable (is only one way), fit the two connectors you removed in the beginning, and you're finshed with the hard part.

Fit the bottom part of the cowling again, remember to have all plastic notches in their place. The parts will lock together nicely, fit the 2 screws behind the steering wheel again and also the bottom one.

Place the dash casing in it's place; top first them push in the bottom. Screw it tight in place.

8. Finished.


This is not a hard work and it took me around 25 minutes (including taking the photos). After that my car has started without a problem.

The Switch Assy costed 900 SEK (> 60) but the garage told me they would charge me around 4500 SEK (>300) to do the change. I don't know how they'd charge me so much for this easy job and now that I know how easy it was, I'd never accept a bill from them with that amount.

I hope this workshop will help somebody in the future, if so, please post you comments on it.

Good luck. :)

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#2 GnzYza

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Posted 21 November 2005 - 08:15 PM

hey Rvall, got it done then!!

Nice How to tutorial you've made.
I bet car starts first time, click---vrooom :D

#3 Rvall

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Posted 25 November 2005 - 10:54 AM

Hi GnzYza.

Yes, I finally got it done. Thanks a lot for your help.

Since I was about to do it and had a camera nearby, I thought I'd take some pictures...

When I was done, it turned out it could be a complete workshop, so here it is.

Roger

#4 Slip

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Posted 12 May 2006 - 07:24 AM

Thank you for making this toturial Rvall!!

My Avensis have now the same problems as you have discribed earlier. I'll try to replace this switch shortly! And now it even looks easy :)

#5 Peterander

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Posted 12 May 2006 - 03:09 PM

THANK YOU Rvall. :thumbsup:

I found this workshop while waiting for my membership confirmation e-mail to post the following question yesterday:

"Hi folks, looks like a very helpful site you have here.
I have a problem with my 1998 Avensis 1.8 GS.
Yesterday When i tried to start her there was nothing beyond the ignition lights,
no attempt to turn over not even a click- nothing. This morning it started fine so took it on a long run
to fully charge battery then when i switched off and tried to start again, same thing, nothing for
a few attempts then it turned over and started normally.
Im hoping someone might recognise this problem as maybe a relay fault or
something.

Thanks

P.S. Its been unusually warm the past two days."



Thanks to you and this site the part has been bought (57) and fitted in 30 mins (15 trying to get the golden screw back in under the cowling ).


Peter.

#6 Slip

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Posted 15 May 2006 - 07:15 PM

Hey - it worked! I've actually changed the part in 30 mins, and seriously impressed my wife!! (who expected me to use the whole night) :)


Thanks again Rwall!! :D



And If anyone else wold like create any repair-guides my wishes are:
  • how to repair front seat heat
  • econo/power indicator in dashboard (displays if the lean-burn system is active or not at the 1.8 engine)
  • replacing front brake discs
  • and replacing the side door list/fenders. On my car three of the are broken due to ice building up on them in the winter, when you open the door the ice bends in behind the fender and the edge of the fender breaks up.


#7 Rvall

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Posted 19 May 2006 - 07:05 AM

Hey - it worked! I've actually changed the part in 30 mins, and seriously impressed my wife!! (who expected me to use the whole night) :)


When will they understand that we are not so stupid as we looks, eeh..., as they think, I mean. ;-P

I'm glad that this has helped some out there. I must also say thank's to GnzYza once again who guided me in the first place.

And If anyone else wold like create any repair-guides my wishes are:
...
and replacing the side door list/fenders. On my car three of the are broken due to ice building up on them in the winter, when you open the door the ice bends in behind the fender and the edge of the fender breaks up.


Isn't this a strange thing for Toyota? I've had 6 cars in my life time, 3 of them has been Toyota and all 3 have had this problem with the lists. No other car has had it????
On my first, I talked to the garage about it and they said that they need to change all lists for it to look nice (they weren't exactly new so from an estetic point of view, I agree...) and it would cost something around 3000 SEK (200). Guess what I told them? :P That would be about 5% of the total value of the car.

On that one I bought a special glue made for boats and rough weather and glued it in place. Not a good solution but it worked for the time being. The glue only held on for about a year, so replacing it is much better.

If anyone has actually replaced them, please post how you did it. Only a short guideline is enough as a start.

#8 paddymck

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Posted 27 July 2006 - 03:54 PM

Rvall
You made me one happy man. I found the information on this site about the problem and then got a part on ebay for a tenner. I was about to try changing it and was thinking I had to remove the steering wheel, air bag and all - not happy. Anyway I found this and finished the job in 10 minutes, seven screws out and back in again. my toyota dealer wanted 240 :crybaby: and a mechanic friend who I told about the heat problem thought I was having a laugh :lol: .
Thanks, your instructions are through to the letter.
Paddy

#9 Rvall

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Posted 14 September 2006 - 09:58 AM

>paddymck

Glad I could help you.
I know the feeling you had before starting the project and that's what made me think of doing a tutorial.
I tried to make it as easy as possible.

I've changed server for the pictures, so If the pictures doesn't show, please send me a mail to
rvall67@hotmail.com

As you know, hotmail is the perfect target for spam, so please put something in the subjectline about Toyota Avensis or like, so I'll recognize it from the junk mails...


Rvall

#10 jejje

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Posted 13 June 2007 - 02:39 PM

Hi Rvall,
I have had the same problem with my Avensis 1.8 VVTI 2000 for every summer (when it was hot weather) for the last couple of years. My Toyota dealer couldn't find out of the problem.
Last week we had temperatures about 30C every day, which caused a lot of startproblems.
Something had to be done, so after I have seen your excellent description how to change it, I bought the part and got it done yesterday. It took 15 minutes. My wife got very impressed of my mechanical skills !
Starts every time now! WROOOOOM
So, thanks a lot Rvall

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