heating TOYOTA AVENSIS 2002 Repair Manual

760W5±01
B50319
Protective
Tape
B67149
Double±sided Tape
± EXTERIOR/INTERIOR TRIMOUTSIDE MOULDING LH
76±21
AVENSIS REPAIR MANUAL (RM1018E)
OUTSIDE MOULDING LH
REPLACEMENT
HINT:
On the RH side, use the same procedures as on the LH side.
1. REMOVE OUTSIDE MOULDING LH
(a) Using a heat light, heat the moulding.
Heating temprature: 40 ± 60C (104 ± 140F)
NOTICE:
Do not heat the moulding excessively.
(b) Tie both the piano wire ends to a wooden block or a similar
object.
(c) Scrape tape off by pulling the piano wire and remove the
moulding with reference pins remaining on the moulding.
NOTICE:

If reusing the moulding, take care not to damage the
moulding.

Do not damage the body.
(d) Remove the moulding.
2. INSTALL OUTSIDE MOULDING LH
(a) Using a heat light, heat the body surface.
Heating temprature: 40 ± 60C (104 ± 140F)
NOTICE:
Do not heat the body excessively.
(b) Remove the tape from the body.
(c) Wipe off the stains with cleaner.
(d) Clean the moulding (if reusing the moulding).
(1) Using a heat light, heat the moulding.
Heating temprature: 20 ± 30C (68 ± 86F)
NOTICE:
Do not heat the moulding excessively.
(2) Remove the tape from the moulding.
(3) Wipe off the stains with cleaner.
(4) Apply new double±sided tape to the moulding as
shown in the illustration.

B67150mm (in.) 16.2 (0.638)
28 (1.102)
228.7 (9.004)243 (9.567)
243 (9.567) 2.3 (0.091)
3.8 (0.150)
252.7 (9.949)119 (4.685)
16.4 (0.646)
76±22
± EXTERIOR/INTERIOR TRIMOUTSIDE MOULDING LH
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using a heat light, heat the body and moulding.
Heating temperature:
Body40 ± 60
C (104 ± 140
F)
Moulding20 ± 30
C (68 ± 86
F)
NOTICE:
Do not heat the body and moulding excessively.
(f) Remove the peeling paper from the face of the moulding
and attach the moulding securely to the vehicle body.
NOTICE:
Be careful that dirt or foreign objects do not stick to adhe-
sive part when removeing the peeling paper.
(g) Push the moulding to the body, as shown in the illustra-
tion.
NOTICE:
Do not apply excessive force onto the moulding. Instead,
apply steady pressure with your thumbs.

760WD±01
B67161
Clip
B67162
Clip
B67163
Double±sided Tape
76±30
± EXTERIOR/INTERIOR TRIMREAR SPOILER (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
REAR SPOILER (WAGON MODELS)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal.
1. REMOVE BACK DOOR TRIM PANEL ASSY UPPER
(a) Remove the 4 clips and door trim panel.
(b) Remove the 4 hole plugs.
2. REMOVE REAR SPOILER
(a) Disconnect the stop lamp connector.
(b) Remove the 6 nuts and clip.
(c) Using a heat light, heat the spoiler.
Heating temprature: 40 ± 60C (104 ± 140F)
NOTICE:
Do not heat the spoiler excessively.
(d) Lightly lift the spoiler at the right end or the left end.
(e) Cut the tape.
(1) Tie both piano wire ends to a wooden block or simi-
lar object.
(2) Cut the tape by pulling the piano wire.
NOTICE:

If reusing the rear spoiler, take care not to damage it.

Be careful not to damage the back door.
(f) Remove the spoiler.
3. INSTALL REAR SPOILER
(a) Clean the surface on the back door where the spoiler is
to be attached.
(1) Using a heat light, heat the back door contact sur-
face.
Heating temprature: 40 ± 60C (104 ± 140F)
NOTICE:
Do not heat the back door excessively.

B67164
Double±sided Tape
± EXTERIOR/INTERIOR TRIMREAR SPOILER (WAGON MODELS)
76±31
AVENSIS REPAIR MANUAL (RM1018E)
(2) Remove the tape from the back door.
(3) Wipe off the stains with cleaner.
(b) When reusing the spoiler:
Clean the spoiler.
(1) Using a heat light, heat the spoiler.
Heating temprature: 20 ± 30
C (68 ± 86
F)
NOTICE:
Do not heat the spoiler excessively.
(2) Remove the tape from the spoiler.
(3) Wipe off the stains with cleaner.
(c) Install the spoiler.
(1) Using a heat light, heat the door and spoiler.
Heating temperature:
Door40 ± 60
C (104 ± 140
F)
Spoiler20 ± 30
C (68 ± 86
F)
NOTICE:
Do not heat the door and spoiler excessively.
(2) Apply new double±sided tape to the spoiler, as
shown in the illustration.
(3) Remove the peeling paper from the spoiler.
NOTICE:
Be careful that dirt or foreign objects do not stick to the
adhesive part when removing the peeling paper.
(4) Install the spoiler with the 6 nuts.
Torque: 9.8 N
m (99 kgf
cm, 87 in.
lbf)
NOTICE:
Do not apply excessive force onto the spoiler. Instead, ap-
ply steady pressure with your thumbs.
(5) Connect the stop lamp connector.
(6) Install the 4 hole plugs.

760WE±01
B67742
B67741
Front Side
Rear Side 1.3 (0.051)
mm (in.) A
A A ± A
4.8 (0.189)
1.5 (0.059)
A ± AA
A
4.6 (1.811)
76±26
± EXTERIOR/INTERIOR TRIMROOF DRIP SIDE FINISH MOULDING CENTER LH
AVENSIS REPAIR MANUAL (RM1018E)
ROOF DRIP SIDE FINISH MOULDING CENTER LH
REPLACEMENT
HINT:
Use the same procedures on the RH side as on the LH side.
1. REMOVE ROOF DRIP SIDE FINISH MOULDING
CENTER LH
(a) Put the protective tape around the circumference of the
moulding.
(b) Using a remover for the roof moulding, release the disen-
gage the clips both in the front and rear ends of the mould-
ing, and then remove the moulding.
NOTICE:

Do not remove the clips.

If that the clips are damaged or removed accidentally,
exchange them for supplied ones.
2. INSTALL ROOF DRIP SIDE FINISH MOULDING
CENTER LH
NOTICE:
Only when exchanging the clips.
(a) Remove the tape that remains on the mounting surface
of the body, and then clean the surface with white gaso-
line.
(b) Using a heat light, heat up the clip installation surfaces of
the body and moulding.
Heating temperature:
Body40 ± 60C (104 ± 140F)
Moulding20 ± 30C (68 ± 86F)
NOTICE:
Do not heat the moulding and body excessively.
(c) Set the supplied clips in the positions as shown in the il-
lustration and press±fit them by hand to install them.
NOTICE:
Install the moulding when 30 minutes or more have passed
after press±fitting the clips.
HINT:

Initial hardening time: 30 minutes

Perfect hardening time: 24 hours

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.

550ZG±01



I12508
Connector B
DTC Check Harness
Current DisplayControl PanelPast Record DTC Display
Memory Clear Button
DTC Calling Button
DTC Calling ButtonºHeatingº
Symbol In Normal
In Malfunction Connector A
± HEATER & AIR CONDITIONERCOMBUSTION 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 automatic operation, so
the burner heater does not activate. (For other failures, similarly activated.)

The cause of failures (such as voltage malfunction, overheating malfunction, 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.

± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
55±17
AVENSIS REPAIR MANUAL (RM1018E)
5. DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit listed for the 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.
012Overheating
Check temperature at temperature or overheating sensor >
125
C
Check water circuit.
014Possible overheating detected
(Hardware threshold value)
Difference of measured values at temperature sensor > 15
C
(min. 70
C water temperature and metering pump in opera-
tion);
Check temperature sensor and overheating sensor, replace if
necessary.
017Overheating detected
(Hardware threshold value)
Temperature at temperature or overheating sensor > 130
C,
emergency OFF if DTC No. 012 or 014s not applicable;
Check water circuit, temperature sensor and overheating sen-
sor, 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 the lead to combustion air motor (burner motor) for
continuity, replace if necessary.
032Combustion air blower motor short±circuit
Check combustion air blower motor (burner motor), replace if
necessary.
Check supply lead (chafed, etc.).
047Metering pump short±circuitCheck the supply lead to metering pump for short±circuit,
check metering pump, replace if necessary.
048Metering pump breakCheck the supply lead to metering pump for continuity, remedy
break, replace metering pump if necessary.
051Cold blow time exceeded
At start, if flame sensor above 70
C, > 240 sec.;
Check exhaust gas combustion air supply, check flame sen-
sor, replace if necessary.
052Safety time exceeded
When all perm. start attempts used up;
Check the fuel delivery and fuel supply.
Check exhaust gas and combustion air ducts.
054Flame cutout, High settingCheck the fuel delivery and fuel supply.
Check exhaust gas combustion air ducts.
056Flame cutout, LOW setting
Check exhaust gas combustion air ducts.
If combustion OK
Check the flame sensor, replace if neces-
sary.
060Temperature control sensor break
Check connecting leads.
Resistance value between 2 and 10 connector B > 2 M
(if
break)
061Temperature control sensor short±circuit
Check connecting leads.
Resistance value between 2 and 10 at connector B < 2 M
(If
short± circuit)
064Flame sensor break
Check connecting leads.
Resistance value between 7 and 14 at connector B > 3,040

(If break)
065Flame sensor short±circuit
Check connecting leads.
Resistance value between 7 and 14 at connector B > 780
(If
short±circuit)

01±18
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

Confirm that the VSC warning light blinks.

VSC system will be reset when the engine is re-
started.

Fasten the vehicle with lock chains.
(b) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and re-
moval as it might disorder the adjustment of related
parts to VSC.
(2) Be sure to carry out the preparation for operation
and the confirmation of operation completion in ac-
cordance with the instruction of the text and when
the related operations to VSC are performed.
10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline flows into the converter, it may cause overheating and is a
fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
create an extra load on the converter.

190JE±02
A82619
Light Lightning Time
Water Temperature ±20 0 28 0
±4 32 (
F) (
C)
82.4 (sec.)
10
3
1
A72562
Pre±heating Time (sec)Battery Voltage [V]
A80155
After Glow Time
Water Temperature68 104 (
F) 020 40(
C) (sec.)
1 19±30
± STARTING & CHARGINGPRE±HEATING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
PRE±HEATING SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
NOTICE:
Turn the ignition switch OFF for 60 seconds before performing the following inspections.
1. INSPECT LIGHTING DURATION OF GLOW INDICA-
TOR LIGHT
(a) Turn the ignition switch ON, and measure the lighting
duration.
Light lighting duration: Refer to the chart graph
2. INSPECT PRE±HEATING
(a) Turn the ignition switch ON, measure how long it takes to
the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
(b) Turn the ignition switch STA, check that the battery volt-
age applied to the glow plugs.
SST 09082±00030, 09083±00150
(c) While cranking the engine, measure how long it takes to
the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
3. INSPECT AFTER GLOW TIME
(a) After the engine starting, measure how long it takes to the
battery voltage is applied to the terminal SREL of the
ECM.
After glow time: Refer to the chart graph