TOYOTA AVENSIS 2002 Repair Manual

I35276
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

Compressor oil ND±OIL 8 or equivalentCooler Thermistor No.1
Auto A/C:
Airmix No.2 Damper
Servo Sub±assy
Heater Piping CoverMode Damper Servo
Sub±assy
Airmix Damper Servo Sub±assy
w/o Hot gas heater:
Cooler Expansion Valve
Cooler Evaporator
Sub±assy No.1
Cooler Unit Drain Hose No.1
Air Conditioning
Tube Assy
Heater Radiator Unit Sub±assyAir Duct No.1Air Duct No.2
w/o Hot gas heater:
Air Conditioning
Tube Assy
w/ Hot gas heater:
O±ring


O±ring


3.5 (35, 30 in.
lbf)
Cooler Air Hose
RHD Auto A/C:
Air Conditioning
Wire No.1
55±54
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)

5507E±03
AC2810
AC2811
N11084
Wrong Okay
HI
LO HI LO
± HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
55±1
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cold water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a hospital or see a physician for profes-
sional treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system, oil lu-
brication will be insufficient and compressor may burnout may
occur, so take care to avoid this, necessary care should be tak-
en.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILE COMPRESSOR IS OPERATING
Open and close the only low pressure valve. If the high pressure
valves are opened, refrigerant flows in the reverse direction and
cause the charging cylinder to rupture.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating, etc.

55±2
± HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
9. DO NOT OPERATE ENGINE AND COMPRESSOR
WITH NO REFRIGERANT IS FILLED
CAUTION:
This may damage the inside of the compressor because
the compressor parts always moves regardless of whether
the A/C system is turned on or off.

550ZC±01
I35425
Dry Cell BatteryMPa
3.19
0.1 0.5 1.0 4.8 4.9 (V) (+) (±) 1
2
3
0.39
0
I35437
Wire Harness Side:
Connector ºBº Connector ºAº
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
55±3
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT AIR CONDITIONER PRESSURE SENSOR
(a) Disconnect the pressure SW connector.
(b)Install the manifold gauge set (See page 55±38).
(c) Connect the positive (+) lead from the three 1.5 V dry cell
batteries to terminal 3 and negative (±) lead to terminal 1.
(d) Check the voltage between terminals 2 and 1 of pressure sensor.
Standard:
The voltage varies with on the refrigerant pressure as
shown in the chart.
2. INSPECT AIR CONDITIONING CONTROL ASSY
(a) Disconnect the connector from air conditioning control assy and inspect the connec\
tor on wire harness side, as shown in the table.
Symbols
(Terminal No.)ConditionSpecified condition
IG (B1) ± GND (B40)Ignition switch: LOCK
ON0
10 to 14 V
+B (B2) ± GND (B40)Always10 to 14 V
GND (B40) ± Body groundAlwaysContinuity
If circuit is not as specified, try replacing the air conditioning control\
assy with a new one. If the circuit is not
as specified, inspect the circuits connected to the other parts.

I36091
From Back Side:
Connector ºBº Connector ºAº 55±4
± HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(b) Connect the connector to air conditioning control assy and inspect wire harness side connector from
the back side, as shown in the table.
Symbols
(Terminal No.)ConditionSpecified condition
HI (A4)± GND (A1)Ignition switch ON
Turn blower dial: OFF  HINo continuity  Continuity
M2 (A5) ± GND (A1)Ignition switch: ON
Turn blower dial: OFF  M2No continuity  Continuity
M1 (A6) ± GND (A1)Ignition switch: ON
Turn blower dial: OFF  M1No continuity  Continuity
GND (A1) ± Body groundIgnition switch: ON
Turn blower dial: OFF  LONo continuity  Continuity
RDEFIN (B4) ±
GND (B40) (*1)
Ignition switch : ON
Rear DEF switch: ON10 to 14 V
S5±2 (B5) ± GND (B40)Ignition switch: ON5.0 V
S5±3 (B6) ± GND (B40)Ignition switch: ON5.0 V
S5 (B7) ± GND (B40)Ignition switch: ON5.0 V
MPX+ (B9) ± GND (B40)Communication circuit±
FRS (B10) ± GND (B40)Ignition switch: ON
R/F switch: RECIRCURATION  FRESH10 to 14  0 V
REC (B11) ± GND (B40)Ignition switch: ON
R/F switch: FRESH  RECIRCURATION10 to 14  0 V
AOD (B12) ± GND (B40)Ignition switch: ON
Mode control dial: DEF10 to 14 V
AOF (B13) ± GND (B40)Ignition switch: ON
Mode control dial: FACE10 to 14 V
MGV (B14) ±
GND (B40) (*2)
Start engine
Hot gas heater: Operate10 to 14  0 V
AMH (B15) ± GND (B40)Ignition switch: ON
Temperature control dial: MAX HOT10 to 14 V
AMC (B16) ± GND (B40)Ignition switch: ON
Temperature control dial: MAX COOL10 to 14 V
SOL+ (B17) ± GND (B40)Start engine
Compressor: OperatePulse generation
ILL+ (B21) ±
GND (B40)
Ignition switch: ON
Turn light control switch: OFF  ON0  10 to 14 V
HOTGASIN (B22) ±
GND (B40) (*2)
Ignition switch: ON
Heater switch: ON10 to 14 V
CFAN (B23) ± GND (B40)Start engine
Condenser fan: operate10 to 14  0 V
RPTC1 (B28) ± GND (B40)PTC heater: OperateAbove 7.5 V
MPX± (B29) ± GND (B40)Communication circuit±
TE (B31) ± GND (B40)Evaporator temperature: 0
C (32
F) 15
C (59
F)2.0 to 2.4  1.4 to 1.8 V

± HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
55±5
AVENSIS REPAIR MANUAL (RM1018E)Symbols
(Terminal No.)Specified condition Condition
PRE (B32) ± GND (B40)Start engine
Refrigerant pressure: 0 Pa (0 kgf/cm2, 0 psi)
3,138 MPa (32.0 kgf/cm2, 455 psi)0.5 to 4.8 V
TPM (B33) ± GND (B40)Ignition switch: ON
Mode control dial: DEF
FACE1
4 V
TP (B34) ± GND (B40)Ignition switch: ON
Temperature control dial: MAX HOT
MAX COOL1
4 V
HRIN (B35) ± GND (B40)Ignition switch: ON
Front blower: OperateBelow 1.0 V
SG±2 (B36) ± Body groundAlwaysContinuity
SG±3 (B37) ± Body groundAlwaysContinuity
SG (B38) ± Body groundAlwaysContinuity
SG±4 (B39) ± Body groundAlwaysContinuity
GND (B40) ± Body groundAlwaysContinuity
PBLT (B24) ± GND (B40)Ignition switch: ON
Seat belt signal: OFF
ON10 to 14
Below 1.0 V
PBKIG (B25) ± GND (B40)Ignition switch: ON
Parking brake switch: OFF
ON10 to 14
Below 1.0 V
ALT (B26) ± GND (B40)Start enginePulse generation
(*1) Petrol only
(*2) Diesel (standard) only
If circuit is not as specified, try replacing the air conditioning control assy with a new one. If circuit is not as
specified, inspect the circuits connected to other parts.

550RQ±02
55±6
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Whole functions of the A/C system does not operate.
4. ECU±B fuse
5. A/C amplifier assy
6. Wire harness or connector±
55±3 ±
Air Flow Control : No blower operation
1. Blower resistor
2. Heater relay
3. Blower w/ fan motor sub±assy
4. A/C amplifier assy
5. Wire harness or connector55±7
55±7
55±7
55±3±
Air Flow Control : No blower control
1. Blower w/fan motor sub±assy
2. Blower resistor
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3
±
Air Flow Control : Insufficient air out
1. Blower w/fan motor sub±assy
2. Blower resistor
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3±
Temperature Control : No cool air comes out
1. Volume of refrigerant
2. Drive belt tension
3. Refrigerant pressure
4. Cooler compressor assy
5. Pressure sensor
6. Condenser fan
7. Air mix damper servo sub±assy
8. A/C amplifier assy
9. Wire harness or connector55±24
55±46
55±2455±7
55±3 ±
55±7
55±3 ±
Temperature Control : No warm air comes out
1. Engine coolant volume
2. Cooler thermistor No.1
3. Air mix damper servo sub±assy
4. A/C amplifier assy
5. Heater radiator unit sub±assy
6. Wire harness or connector55±7
55±3
55±7
55±3±
±
Temperature Control : Output air is warmer or cooler than the set
temperature or response is slow.1. A/C amplifier assy
2. Air mix damper servo sub±assy
3. Air mix level55±3
55±7
±
Temperature Control : No temperature control
1. A/C amplifier assy
2. Air mix damper servo sub±assy
3. Air mix level55±3
55±7±
No air inlet control
1. Recirculation damper servo sub±assy
2. A/C amplifier assy
3. Wire harness or connector55±7
55±3±
No air outlet control
1. A/C amplifier assy
2. Mode damper servo sub±assy
3. Mode lever55±3
55±7±
Engine idle up does not occur, or is continuous
1. Idle up switch
2. Cooler compressor assy
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3±
Brightness does not changes when rheostat volume or light con-
trol switch it turned.1. Illumination light system
2. A/C amplifier assy
3. Wire harness or connector±
55±3 ±

550ZD±01

E61224
E32877
± HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
55±7
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT COMPRESSOR (MANUAL AIR
CONDITIONING)
(a) Measure the resistance between terminals 1 and 2.
Resistance: 10 to 11
at 25
C (77
F)
If the resistance is not as specified, replace the compressor
assy.
2. INSPECT BLOWER RESISTOR (MANUAL AIR
CONDITIONING)
(a) Measure resistance between terminals, as shown in the
table.
Tester connectionSpecified condition
1 ± 21.404 to 1.716

1 ± 30.504 to 0.616

1 ± 43.024 to 3.696

If resistance is not as specified, replace the blower resistor.

I36092
LHD Models:REC
FRS
I36094
I36093
RHD Models:
RECFRS
I36094
55±8
± HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
3. INSPECT RECIRCULATION DAMPER SERVO
SUB±ASSY (MANUAL AIR CONDITIONING)
(a) Inspect servomotor operation.
(1) Connect the positive (+) lead from the battery to ter-
minal 3 and negative (±) lead to terminal 2, then
check that the arm turns to ºFRSº side smoothly.
(2) Connect the positive (+) lead from the battery to ter-
minal 3 and negative (±) lead to terminal 1, then
check that the arm turns to ºRECº side smoothly.
If operations are not as specified, replace the mode damper
servomotor.

I30157
I30162
To ºMAX HOTº
To ºMAX COOLº
± HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
55±9
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT AIRMIX DAMPER SERVO SUB±ASSY
(MANUAL AIR CONDITIONING)
(a) Inspect servomotor operation.
(1) Connect the positive (+) lead from the battery to ter-
minal 4 and negative (±) lead to terminal 5, then
check that the arm turns to ºMAX COOLº side
smoothly.
(2) Connect the positive (+) lead from the battery to ter-
minal 5 and negative (±) lead to terminal 4, then
check that the arm turns to ºMAX HOTº side
smoothly.
If operations are not as specified, replace the servomotor.