TOYOTA AVENSIS 1999 Supplement

– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–11
5. ON–VEHICLE INSPECTION
If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table
below and proceed to the appropriate page.
DTC No.Description of faultComment / Remedy
000No malfunction–
010
011Overvoltage shutoff
Undervoltage shutoffVoltage between 1 and 5 at connector A > 16 V
Voltage between 1 and 5 at connector A < 10.2 V
(Voltage values must be present > 20 seconds)
Check battery, regulator and electrical leads.
012OverheatingCheck temperature at temperature or overheating sensor >
125C.
Check water circuit.
014Possible overheating detected
(Hardware threshold value)Difference of measured values at temperature sensor > 15C
(min. 70C water temperature and metering pump in opera-
tion);
Check temperature sensor and overheating sensor, replace if
necessary.
017Overheating delected
(Hardware threshold value)Temperature at temperature or overheating sensor > 130C,
emergency OFF if DTC No. 012 or 014 not applicable;
Check water circuit, check temperature sensor and overheat-
ing sensor, replace if necessary.
020Glow plug breakCheck glow plug, replace if necessary.
021Glow plug output overloadCheck glow plug, replace if necessary.
030Combustion air blower motor
EMF outside perm. range.Blower impeller or burner motor fammed (frozen solid, dirty,
etc.)
Remedy jam, replace burner motor if necessary.
031Combustion air blower motor breakCheck lead to combustion air motor (burner motor) for continu-
ity, replace if necessary.
032Combustion air blower motor short–circuitCheck combustion air blower motor (burner motor), replace if
necessary.
Check supply lead (chafed, etc.).
047Metering pump short–circuitCheck supply lead to metering pump for short–circuit, check
metering pump, replace if necessary.
048Metering pump breakCheck supply lead to metering pump for continuity, remedy
break, replace metering pump if necessary.
051Cold blow time exceededAt start, if flame sensor above 70C > 240 sec.;
Check exhaust gas combustion air supply, check flame sen-
sor, replace if necessary.
052Safety time exceededWhen all perm. start attempts used up;
Check fuel delivery and fuel supply.
Check exhaust gas and combustion air ducts.
054Flame cutout, HIGH settingCheck fuel delivery and fuel supply.
Check exhaust gas and combustion air ducts.
056Flame cutout, LOW setting
Check exhaust gas and combustion air ducts.
If combustion OK → Check flame sensor, replace if neces-
sary.
060Temperature sensor breakCheck connecting leads.
Resistance value between 6 and 13 at connector B > 2 MΩ
If break)
061Temperature sensor short–circuitCheck connecting leads.
Resistance value between 6 and 13 at connector B < 2 MΩ
(If short–circuit)

AC–12
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
DTC No.
Description of faultComment / Remedy
064Flame sensor breakCheck connecting leads.
Resistance value between 7 and 14 at connector B > 3,040 Ω
(If break)
065Flame sensor short–circuitCheck connecting leads.
Resistance value between 7 and 14 at connector B > 780 Ω
(If short–circuit)
071Overheating sensor breakCheck connecting leads.
Resistance value between 5 and 12 at connector B > 2MΩ
(If break)
072Overheating sensor short–circuitCheck connecting leads.
Resistance value between 5 and 12 at connector B < 50 Ω
(If short–circuit)
090
092
093Control unit detectice (Intermal fault / Reset)
Control unit detective (ROM error)
Control unit detective (RAM error)Control unit malfunction due to interference voltage from ve-
hicle electrical system;
Possible causes low batteries, chargers, other sources of
interlerence; eliminale interference voltages.
Internal faults detected in microprocessor / memory detected.
Replace control unit.
097Internal control unit faultsOther faults which cannot lead to DTC No.90, 92 and 93, re-
place control unit.

AC29W–02
I12467
Heater Hose (OUT)
Intake PipeFuel Line
Heater Connector Heater Hose (IN)
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–13
COMPONENTS

I12453
Cover JacketCover Blower
Control Unit and Cover Glow Plug
Flame SensorCable Harness
Electric Motor Complete
Heat Excharger
and JacketCombustion Chamber
with Flame Tube Water Temperature
Sensor Overheat Sensor
Plate
 Gasket  O–Ring
 Gasket
Control Unit and Cover Non–reusable part AC–14
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER

AC29X–01
I12474
I12475
I12476
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–15
REMOVAL
1. REMOVE RH UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT HEATER HOSES
(a) Disconnect the inlet heater hose.
(b) Disconnect the outlet heater hose.
4. DISCONNECT FUEL LINE
Disconnect the fuel line from the fuel pump.
5. DISCONNECT FUEL PUMP CONNECTOR
6. DISCONNECT COMBUSTION TYPE POWER HEATER
CONNECTOR
7. REMOVE COMBUSTION TYPE POWER HEATER
Remove the 2 bolts holding the combustion type power heater
to the 2 brackets.

AC29Y–01
I12445
I12446
I12447
Control Unit
Cover
I12449
I12450
AC–16
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
DISASSEMBLY
1. REMOVE JACKET COVER
Remove the 4 screws and jacket cover.
2. REMOVE BLOWER COVER
Remove the 4 screws and blower cover.
3. REMOVE CONTROL UNIT AND COVER
(a) Remove the 2 screws.
(b) Remove the 2 hexagon screws.
(c) Remove the control unit and cover.
4. REMOVE CABLE HARNESS
(a) Remove the screw and plate.
(b) Remove the water temperature sensor and overheat sen-
sor.
5. REMOVE ELECTRIC MOTER
(a) Remove the 3 screws and the electric moter.
(b) Remove the gasket.

I12451
I12741
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–17
6. REMOVE COMBUSTION CHAMBER WITH FLAME
TUBE
Remove the combustion chamber and gasket.
7. REMOVE HEAT EXCHAMBER

AC29Z–01


 I12509 35
30
25
20
15
5 10
0
0
20
406080 100 120
Temp. (C)
Resistance (kΩ)
Ohmmeter Water Temperature
Sensor
6 13




I12510 35
30
25
20
15
5 10
0
0
20
406080 100 120
Te m p . (C)
Resistance (kΩ)
Overheat Sensor
Ohmmeter
5
12
I12755
Ohmmeter 93
AC–18
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
INSPECTION
1. INSPECT WATER TEMPERATURE SENSOR
Measure the resistance between the terminals 6, 13.
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: Refer to the graph
If the resistance is not as speaified, replace the water tempera-
ture sensor.
2. INSPECT OVERHEAT SENSOR
Measur the resistance between the terminal 5, 12.
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: Refer to the graph
If the resistance is not as speaified, replace the over heat sen-
sor.
3. INSPECT GLOW PLUG
Using an ohmmeter, check that there is continuity, between the
glow plug terminal 3, 9.
Standard resistance: about 0.5ΩC  



If resistance is over 1Ω, replace the glow plug.


I12497
–50
Resistance kΩ
0 50 150100 450 500 550 2
1.75 2.25
0.5 0.751 1.251.5
350 300 250 200 400 2.5 2.753
7 14
Ohmmeter
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–19
4. INSPECT FLAME SENSOR
Measur the resistance between the terminal 7, 14.

AC2A0–01
I12452
I12451
I12449
New Gasket
I12447
Control Unit
Cover
I12446
AC–20
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
REASSEMBLY
1. INSTALL HEAT EXCHAMBER
Align slot on heat exchanger (arrow) with lug in jacket.
2. INSTALL COMBUSTION CHAMBER WITH FLAME
TUBE
Install a new gasket and the combustion chamber.
3. INSTALL ELECTRIC MOTOR
(a) Install a new gasket.
(b) Install the electric motor with the 3 screws.
4. INSTALL CABLE HARNESS
(a) Install the water temperature sensor and over heat sen-
sor.
(b) Install the plate with the screw.
5. INSTALL COVER AND CONTROL UNIT
(a) Install the cover and control unit.
(b) Install the 2 hexagon screws.
(c) Install the 2 screws.
6. INSTALL BLOWER COVER
Install the blower cover with the 4 screws.