TOYOTA AVENSIS 2003 Service Repair Manual

To Ignition SW
IG Terminal
Test Light
Relay
Light
SW 2 Solenoid DisconnectShort [A]
Disconnect
Disconnect SW 1Fuse Case
Short [B]
Short [C]
Pull Up
Press Down Press Down Pull Up
AVENSIS (EWD526E)
13
C
FINDING A SHORT CIRCUIT
(a) Remove the blown fuse and disconnect all loads of the fuse.
(b) Connect a test light in place of the fuse.
(c) Establish conditions in which the test light comes on.
Example:[A]–Ignition SW on
[B] –Ignition SW and SW 1 on
[C] –Ignition SW, SW 1 and Relay on (Connect the
Relay) and SW 2 off (or Disconnect SW 2)
(d) Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light
stays lit and the connector where the light goes out.
(e) Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
(a) Do not open the cover or the case of the ECU unlessabsolutely necessary. (If the IC terminals are touched,
the IC may be destroyed by static electricity.)
(b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or
clothing comes in contact with the terminals of leads
from the IC, etc. of the replacement part (spare part).
DISCONNECTION OF MALE AND FEMALE
CONNECTORS
To pull apart the connectors, pull on the connector itself, not
the wire harness.
HINT : C h e c k t o s e e w h a t k i n d o f c onnector you are
disconnecting before pulling apart.
http://vnx.su






(mm)
Reference:
Tool
Up
Example:
(Case 1)
Terminal Retainer
Terminal Retainer
[Retainer at Full Lock Position]
[Retainer at Temporary Lock Position] Stopper
Terminal
Retainer
Secondary
Locking Device
Example:
(Case 2)
14
AVENSIS (EWD526E)
C TROUBLESHOOTING
HOW TO REPLACE TERMINAL
(with terminal retainer or secondary locking device)
1. PREPARE THE SPECIAL TOOL
HINT : To remove the terminal from the c onnector, please
construct and use the special tool or like object shown on
the left.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
(a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from
the connector.
(b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTICE:
Do not remove the terminal retainer from connector body.
[A] For Non–Waterproof Type Connector
HINT : The needle insertion position varies according to the connector ’s shape (number of terminals etc.), so
check the position before inserting it.
”Case 1” Raise the terminal retainer up to the temporary lock
position.
”Case 2 ”
Open the secondary locking device.
http://vnx.su

Tool
Ta b
Ta b
Terminal
Retainer
Access Hole ( Mark) Tool
Tool [Female]
Example:
[Male]
(Case 1)
[Male]
[Female]
Retainer
at Full Lock Position
Retainer
at Temporary Lock Position
Terminal Retainer
[Male] Press Down
[Female]Press Down Tool
Tool
Example:
(Case 2)
AVENSIS (EWD526E)
15
C
[B] For Waterproof Type Connector
HINT : Te r m i n a l r e t a i n e r c o l o r i s d i ff e r e n t according to connector body.
Example:
Terminal Retainer
: Connector Body
Black or White : Gray
Black or White : Dark Gray
Gray or White : Black
”Case 1” Type where terminal retainer is pulled
up to the temporary lock position (Pull
Type).
Insert the special tool into the terminal
retainer access hole (
Mark) and pull
the terminal retainer up to the
temporary lock position.
HINT : The n eedle insertion position varies
according to the connector ’s shape
(Number of terminals etc.), so check
the position before inserting it.
”Case 2” Type which cannot be pulled as far as
Power Lock insert the tool straight into
the access hole of terminal retainer as
shown.
http://vnx.su

Retainer at
Full Lock Position[Male] [Female]
Retainer at
Temporary Lock Position
Locking Lug
Tool
16 AVENSIS (EWD526E)
C TROUBLESHOOTING
Push the terminal retainer down to the temporary lock position.
(c) Release the locking lug from terminal and pull the terminal out
from rear.
4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal until the locking lug locks firmly.
3. Insert the terminal with terminal retainer in the temporary lock position.
(b) Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
http://vnx.su

∗The titles given inside the components are the names of the terminals (\
terminal codes) and are not treated as being
abbreviations.
AVENSIS (EWD526E) 17
ABBREVIATIONS D
ABBREVIATIONS
The following abbreviations are used in this manual.
A/C = Air Conditioner
A/T = Automatic Transaxle
ABS = Anti–Lock Brake System
CIS = Commonwealth of Independent States
DLC3 = Data Link Connector 3
EC = Electrochromic
ECT = Electronic Control Transmission
ECU = Electronic Control Unit
EFI = Electronic Fuel Injection
EGR = Exhaust Gas Recirculation
EPS = Electric Power Steering
ESA = Electronic Spark Advance
EVAP = Evaporative Emission
HID = High Intensity Discharge
INT = Intermittent
ISC = Idle Speed Control
J/B = Junction Block
L/B = Liftback Type
LH = Left–Hand
LHD = Left–Hand Drive
M/T = Manual Transaxle
PTC = Positive Temperature Coefficient
R/B = Relay Block
RH = Right–Hand
RHD = Right–Hand Drive
S/D = Sedan Type
SRS = Supplemental Restraint System
SW = Switch
TEMP. = Temperature
TRC = Traction Control
VRV = Vacuum Regulating Valve
VSC = Vehicle Stability Control
VSV = Vacuum Switching Valve
VVT = Variable Valve Timing
VVT–i = Variable Valve Timing–intelligent
W/G = Wagon Type
w/ = With
w/o = Without
http://vnx.su

18AVENSIS (EWD526E)
E GLOSSARY OF TERMS AND SYMBOLS
BATTERY
Stores chemical energy and
converts it into electrical energy.
Provides DC current for the auto’s
various electrical circuits.GROUNDThe point at which wiring attaches to
the Body, thereby providing a return
path for an electrical circuit; without a
ground, current cannot flow.
CAPACITOR (Condenser)A small holding unit for temporary
storage of electrical voltage.HEADLIGHTSCurrent flow causes a headlight
filament to heat up and emit light. A
headlight may have either a single
(1) filament or a double (2) filament
1. SINGLE
FILAMENT
CIGARETTE LIGHTER
An electric resistance heating
element.2. DOUBLE
FILAMENT
CIRCUIT BREAKERBasically a reusable fuse, a circuit
breaker will heat and open if too
much current flows through it.
Some units automatically reset when
cool, others must be manually reset.HORNAn electric device which sounds a
loud audible signal.
DIODEA semiconductor which allows
current flow in only one direction.IGNITION COILConverts low–voltage DC current
into high–voltage ignition current for
firing the spark plugs.
DIODE, ZENER
A diode which allows current flow in one
direction but blocks reverse flow only up
to a specific voltage. Above that potential,
it passes the excess voltage. This acts as
a simple voltage regulator.LIGHTCurrent flow through a filament
causes the filament to heat up and
emit light.
PHOTODIODEThe photodiode is a semiconductor
which controls the current flow
according to the amount of light.LED (LIGHT EMITTING DIODE)
Upon current flow, these diodes emit
light without producing the heat of a
comparable light.
DISTRIBUTOR, IIAChannels high–voltage current from
the ignition coil to the individual
spark plugs.METER, ANALOG
Current flow activates a magnetic
coil which causes a needle to move,
thereby providing a relative display
against a background calibration.
FUSE
A thin metal strip which burns through
when too much current flows through it,
thereby stopping current flow and
protecting a circuit from damage.
FUSIBLE LINK
METER, DIGITALCurrent flow activates one or many
LED’s, LCD’s, or fluorescent
displays, which provide a relative or
digital display.
FUEL
A heavy–gauge wire placed in high
amperage circuits which burns through on
overloads, thereby protecting the circuit.
The numbers indicate the crosssection
surface area of the wires.(for Medium Current Fuse)
(for High Current Fuse or
Fusible Link)MOTOR A power unit which converts
electrical energy into mechanical
energy, especially rotary motion.
M
http://vnx.su

AVENSIS (EWD526E)19
E
RELAY
Basically, an electrically operated
switch which may be normally
closed (1) or open (2).
Current flow through a small coil
creates a magnetic field which either
opens or closes an attached switch.
1. NORMALLY
CLOSED
2. NORMALLY
OPEN
SWITCH, MANUAL
Opens and closes
SPEAKERAn electromechanical device which
creates sound waves from current
flow.
RELAY, DOUBLE THROWA relay which passes current
through one set of contacts or the
other.
circuits, thereby
stopping (1) or
allowing (2) current
flow.1. NORMALLY
OPEN
2. NORMALLY
CLOSED
RESISTORAn electrical component with a fixed
resistance, placed in a circuit to
reduce voltage to a specific value.SWITCH, DOUBLE THROWA switch which continuously passes
current through one set of contacts
or the other.
RESISTOR, TAPPED
A resistor which supplies two or
more different non adjustable
resistance values.SWITCH, IGNITIONA key operated switch with several
positions which allows various
circuits, particularly the primary
ignition circuit, to become
operational.
RESISTOR, VARIABLE or RHEOSTAT
A controllable resistor with a variable
rate of resistance.
Also called a potentiometer or
rheostat.
SENSOR (Thermistor)A resistor which varies its resistance
with temperature.SWITCH, WIPER PARKAutomatically returns wipers to the
stop position when the wiper switch
is turned off.
(Reed Switch Type)
SENSOR, SPEEDUses magnetic impulses to open
and close a switch to create a signal
for activation of other components.TRANSISTORA solidstate device typically used as
an electronic relay; stops or passes
current depending on the voltage
applied at ”base”.
SHORT PINUsed to provide an unbroken
connection within a junction block.WIRES Wires are always drawn as
straight lines on wiring
diagrams.
Crossed wires (1) without a
black dot at the junction are
(1) NOT
CONNECTED
SOLENOID
An electromagnetic coil which forms
a magnetic field when current flows,
to move a plunger, etc.
black dot at the junction are
not joined;
crossed wires (2) with a
black dot or octagonal ( )
mark at the junction are
spliced (joined)
connections.
(2) SPLICED
http://vnx.su

20AVENSIS (EWD526E)
F RELAY LOCATIONS
[Engine Compartment]
(Gasoline)
Headlight Cleaner
Control Relay
Engine Room
R/B No.1
Engine Room
J/B No.1
Headlight Control
ECU LH
Skid Control
ECU with
Actuator
(w/ VSC)
Skid Control
ECU with
Actuator
(w/o VSC)
Headlight
Control
ECU RH
Engine Room
R/B No.2
Electronic Driver Unit
Engine Room R/B No.4
Engine Room J/B No.4
(1CD–FTV)
Headlight Cleaner
Control Relay
Engine Room
R/B No.1
Engine Room
J/B No.1
Power Heater
Assembly
Headlight Control
ECU LH
Skid Control
ECU with
Actuator
(w/ VSC)
Skid Control
ECU with
Actuator
(w/o VSC)
Electronic
Driver Unit
Headlight
Control
ECU RH
Engine Room R/B No.2
Glow Plug Relay
Engine Room
R/B No.3
http://vnx.su

AVENSIS (EWD526E)21
F
[Instrument Panel]
(LHD)
Fuse Block
J/B No.6
Wiper Relay
Door Control
Receiver
Headlight Beam
Level Control
ECU
A/C Control
Assembly
Option Connector
(Navigation ECU)
Engine and ECT
ECU (A/T)
Engine ECU (M/T)
Navigation ECUShift Lock
Control ECUAirbag Sensor
Assembly
Driver Side
R/B
Rear Window
Defogger Relay
Turn Signal
Flasher Relay
Rear Fog
Light Relay
Circuit Opening
Relay
Integration
Relay
Driver Side J/B EPS ECU
Transponder Key
AmplifierTransponder Key
ComputerAntenna
AmplifierCenter J/B
(RHD)
Shift Lock
Control ECU
Center J/B
Turn Signal
Flasher Relay
Theft Deterrent
ECU
Headlight Beam
Level Control ECU
Wiper Relay
Fuse Block
J/B No.6
Transponder
Key Amplifier
Airbag Sensor
AssemblyOption Connector
(Navigation ECU)
Driver Side
J/B
Integration Relay
Engine and ECT
ECU (A/T)
Engine ECU
(M/T)
Navigation ECU
Circuit Opening
Relay
Rear Fog
Light Relay
A/C Control
Assembly
Door Control
Receiver
Driver Side
R/BAntenna
AmplifierTransponder
Key ComputerEPS ECURear Window
Defogger Relay
http://vnx.su

22AVENSIS (EWD526E)
F RELAY LOCATIONS
[Body]
(S/D)
Telephone Microphone
AmplifierMoon Roof Control
Relay and Motor
(L/B)
Telephone Microphone
AmplifierMoon Roof Control
Relay and Motor
Rear Wiper
Motor and Relay
http://vnx.su