TOYOTA AVENSIS 2003 Service Repair Manual

I30157
I30162
To ºMAX HOTº
To ºMAX COOLº
±
HEATER & AIR CONDITIONER AIR 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.
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I30157
I30116
To ºDEFºTo ºFACEº
55±10
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT MODE 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 ºDEFº 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 ºFACEº side smoothly.
If operations are not as specified, replace the servomotor.
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E50650
I30145
40
30
20
10 8
6
4
2
0 ±30 ±20 ±10 0 10 20 30 50 60 70 80 40
Resistance (k

)
Temperature (
C)
I30151
2
1
LHD
RHD
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
55±11
AVENSIS REPAIR MANUAL (RM1018E)
6. INSPECT COOLER THERMISTOR NO.1 (MANUAL AIR
CONDITIONING)
(a) Check the resistance between terminal 1 and 2 of cooler
thermistor No. 1 at each temperature, as shown in the
graph.
Standard: 1,500
at 25
C (77
F)
HINT:
As the temperature increases, the resistance decreases.
If resistance value is not as specified, replace the sensor.
7. INSPECT BLOWER W/FAN MOTOR SUB±ASSY
(MANUAL AIR CONDITIONING)
(a) Connect the positive (+) lead from the battery to terminal
1 and negative (±) to terminal 2, then check that the motor
operation smoothly.
If operation is not as specified, replace the blower motor.
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E32993
55±12
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
8. INSPECT HEATER RELAY (M ANUAL AIR
CONDITIONING)
Terminal No.Specified condition
No continuity
3±5Less than 1

(When battery voltage applied to terminals 1 and 2.)
Less than 1

3±4No continuity
(When battery voltage applied to terminals 1 and 2.)
1±2Constant continuity
If continuity is not as specified, replace the rear cooler relay.
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550YQ±01
I35277
Blower Assy
Air Duct No.2
Recirculation Damper Servo Sub±assy
Air FilterAir Filter Case
Blower w/ fan Motor Sub±assy
Manual A/C: Blower Resistor
Air Conditioning Wire No.1
Auto A/C:
Blower Motor Control
9.8 (100, 87 in.
lbf)
Cooler Wiring No.1Manual A/C:
N

m (kgf
cm, ft
lbf): Specified torque
55±64
±
HEATER & AIR CONDITIONER BLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
BLOWER ASSY
COMPONENTS
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550YR±01
I36810Clamp
I36811Clamp
I35314
I35315
±
HEATER & AIR CONDITIONER BLOWER ASSY
55±65
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±64
1.REMOVE INSTRUMENT PANEL LOWER ASSY (See page 71±11)
HINT:
Refer to the instructions for removal of the instrument panel lower assy\
.
2.REMOVE ECM (See page 10±65)
3.REMOVE AIR DUCT NO.2 (See page 55±55)
4. REMOVE BLOWER ASSY
(a) Disconnect the connector and the clamp.
(b) RHD Auto A/C:Disconnect the connector and the clamp.
(c) Disconnect the connectors.
(d) Remove the 2 nuts.
(e) Remove the 2 bolts and the 2 screws.
(f) Release the claw fitting and remove the blower assy.
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I353162 Claws
I35318
I35319Clamp
I35320
55±66
±
HEATER & AIR CONDITIONER BLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE AIR FILTER CASE
(a) Release the 2 claw fittings and remove the air filter case.
6. REMOVE AIR FILTER 7. REMOVE RECIRCULATION DAMPER SERVOSUB±ASSY
(a) Remove the 2 screws and the recirculation damper servo sub±assy.
8. REMOVE AIR CONDITIONING WIRENO1 (MANUAL AIR CONDITIONING)
(a) Disconnect the connector.
(b) Release the clump and remove the air conditioning wire No.1.
9. REMOVE COOLER WIRING NO.1 (AUTO AIR CONDITIONING)
HINT:
Disconnection of the cooler wiring No.1 is the same as the air condition\
ing wire No.1. 10. REMOVE BLOWER RESISTOR (MANUAL AIRCONDITIONING)
(a) Remove the 2 screws and the blower resistor.
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I35321
I35322
I35317
I36813
I35314
±
HEATER & AIR CONDITIONER BLOWER ASSY
55±67
AVENSIS REPAIR MANUAL (RM1018E)
11. REMOVE BLOWER MOTOR CONTROL (AUTO AIR
CONDITIONING)
(a) Remove the 2 screws and the blower motor control.
12. REMOVE BLOWER W/FAN MOTOR SUB±ASSY
(a) Remove the 3 screws and the blower w/ fun motor sub±
assy.
13. INSTALL AIR FILTER
(a) Install the air filter as shown in the illustration.
14. INSTALL BLOWER ASSY
(a) Install the blower assy with the claw fitting.
(b) Install the blower assy with the 2 bolts and the 2 screws. Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf) (Bolt)
(c) Install the 2 nuts.
(d) Connect the connectors.
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I36811Clamp
I36810Clamp
55±68
±
HEATER & AIR CONDITIONER BLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(e) RHD Auto A/C: Connect the connector and the clamp.
(f) Connect the connector and the clamp.
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550ZG±01



I12508
Connector BDTC Check Harness
Current Display Control Panel
Past Record
DTC Display
Memory Clear Button
DTC Calling Button DTC Calling ButtonºHeatingº
Symbol
In Normal
In Malfunction
Connector A
±
HEATER & AIR CONDITIONER COMBUSTION TYPE POWER HEATER SYSTEM
55±15
AVENSIS REPAIR MANUAL (RM1018E)
COMBUSTION TYPE POWER HEATER SYSTEM
ON±VEHICLE INSPECTION
NOTICE:

If the glow plug breaks, the ECU detects the breakage and stops the auto\
matic operation, so
the burner heater does not activate. (For other failures, similarly act\
ivated.)

The cause of failures (such as voltage malfunction, overheating malfunctio\
n, short±circuit or
breakage of functional components, etc.) and repair methods are shown by connecting the DTC
tester and reading the DTC.
1. DIAGNOSTICS FUNCTION
(a) Connect the DTC tester between the connector A (Vehicle harness) of DTC check harness and con- nector B (Power heater harness).
(b) Start the engine.
(c) Pressing the DTC calling button displays a 3±digit number DTC.
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