air condition TOYOTA AVENSIS 2003 Service User Guide

D25083
Vibrate Slightly
Shake Slightly
Vibrate
Slightly
D25084
Malfunction
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±27
AVENSIS REPAIR MANUAL (RM1018E)
SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no symptoms occurs. In such cases\
, a thorough customer
problem analysis must be carried out. Then the same or similar conditions and e\
nvironment in which the
problem occurred in the customer's vehicle should be simulated. No matter how much experience a techni-
cian has, or how skilled he may be, if he proceeds to troubleshoot without c\
onfirming the problem symptoms,
he will tend to overlook something important in the repair operation and make a wrong guess somewhere,
which will only lead to a standstill. For example, for a problem which only o\
ccurs when the engine is cold,
or for a problem which occurs due to vibration caused by the road during d\
riving, etc., the problem can never
be determined when the engine is hot or when the vehicles is at a standsti\
ll. Since vibration, heat or water
penetration (moisture) is a likely cause for the problem which is difficult to reproduce, the symptom simulation
tests introduced here are effective measures in a point that the external causes are applied to the vehicle
in a stationary condition.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms should be confirmed, \
and the problem area or parts
must also be discovered. To do so, reduce the possible problem circuits according to the symptoms before
starting this type of test and have the hand±held tester connected beforehand\
. After that, carry out the symp-
tom simulation test, judging whether the circuit being tested is defective \
or normal and also confirming the
problem symptoms at the same time. Refer to the problem symptoms table of each system to narrow down
the possible causes of the symptom.
1. VIBRATION METHOD: When vibration seems to be
the major cause.
(a) PART AND SENSOR
(1) Apply slight vibration with your finger to the part ofthe sensor considered to be the problem cause and
check whether the malfunction occurs.
HINT:
Applying strong vibration to relays may result in open relays.
(b) CONNECTORS (1) Slightly shake the connector vertically and horizon-tally.
(c) WIRE HARNESS
(1) Slightly shake the wire harness vertically and hori-zontally.
The connector joint and fulcrum of the vibration are
the major areas that should be checked thoroughly.
2. HEAT METHOD: If the problem seems to occur when the area in question is heated.
(a) Heat the component that is the possible cause of the mal- function with a hair dryer or similar object. Check if the
malfunction occurs.
NOTICE:

Do not heat the components to more than 60 C
(140 F) (Temperature is limited to keep the compo-
nents from being damaged).
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SFISFISFISFISFISFI
D25842

Circuit Description
The major role and, operation of the circuit
and its component parts are explained.

Diagnostic Trouble Code No. and Detection Item
Indicates the diagnostic trouble codes, diagnostic
trouble code settings and suspect areas for a
problem.
Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow, SB = Sky Blue
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
Inspection Procedures
Use the inspection procedures to determine
if the circuit is normal or abnormal. If it is ab-
normal, use it to determine whether the prob-
lem is located in the sensors, actuators, wire
harness or ECU.

Indicates the condition of the connector of the ECU
during the check.


Connections of tester are
indicated by (+), (±) after
terminals name.
Connector being checked
is connected.Connector being checked
is disconnected.
For inspection of connector
with body ground, there is
nothing about the body
ground written down.
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±31
AVENSIS REPAIR MANUAL (RM1018E)
CIRCUIT INSPECTION
How to read and use each page is shown below.
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010LF±01






D25016
±
INTRODUCTION REPAIR INSTRUCTION
01±5
AVENSIS REPAIR MANUAL (RM1018E)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1Looks
Always wear a clean uniform.

Hat and safety shoes must be worn.
2Vehicle protection
Set a grill cover, fender cover, seat cover and floor mat before starting operation.
3Safe operation

When working with 2 or more persons, be sure to check the safety of one \
another.

When working with the engine running, pay attention to providing ventila\
tion for exhaust fumes in the work-
shop.

When working with high±temperatures, rotating, moving or vibrating pa\
rts, be careful not to burn or injure
yourself.

When jacking up the vehicle, be sure to support the specified location w\
ith a safety stand.

When lifting up the vehicle, use safety equipment.
4Preparation of tools and
measuring gauge
Before starting repairs, prepare the tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations

Diagnose with a thorough understanding of the trouble condition and perf\
orm effective operation.

Before removing the parts, check the general condition of the assembly, and for deformation and damage.

When the structure is complicated, take a notes or make matchmarks as no\
t to make mistakes that affect the
function of the parts.

Clean and wash the removed parts if necessary and assemble them after a \
thorough check.
6Removed parts

Place the removed parts in the correct order to avoid mixing them up or \
making them dirty.

As for non±reusable parts such as gaskets, O±rings, and self±lo\
cking nuts, replace them with new ones
following the instructions in this manual.

Organize the parts that were replaced in a box and show them to the cust\
omer.
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D25081
Spring Type Clamp
Clamp Track
D20025
CG
DLC3
TS
D30964
±
INTRODUCTION REPAIR INSTRUCTION
01±17
AVENSIS REPAIR MANUAL (RM1018E)
6. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of the insert-
ing portion and the clamp position to restore it surely.
(b) Change a deformed or dented clamp for a new one.
(c) In case of reusing a hose, attach the clamp on the clamp track portion of the hose.
(d) For a spring type clamp, adjust it by adding force to the
arrow mark direction after the installation.
7. FOR VEHICLES EQUIPPED WITH MOBILE COMMU- NICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic sys-
tems. For details of the ECU and sensors locations, refer
to the section on applicable components.
(c) Prevent the antenna feeder from getting entangled with the other wiring, and keep the antenna feeder separate
from other wiring as much as possible.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high±powered mobile communication system.
8. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRC) SYSTEM
(a) NOTICES WHEN USING 2±WHEEL DRUM TESTER
(1) When using a 2±wheel drum tester such as a speedometer tester, a combination tester ofspeedometer and brake, chassis dynamometer or else, always turn the TRC system off via the
TRC OFF switch before measurement.
NOTICE:
TRC system OFF condition can be confirmed by the indication, ºTRC OFF\
º, of the warning light in
the combination meter.
9. FOR VEHICLES EQUIPPED WITH VEHICLE SKIDCONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) When using a drum tester, be sure to start the en-gine with the ignition OFF, and connect SST to the
terminals TS and CG of the DLC3 before measure-
ment in order to prohibit the VSC operation.
SST 09843±18040
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010B5±11
D25082
Rubber Attachment
D27697
: SUPPORT POSITION, PAN
TOGRAPH JACK POSITION
: CENTER OF VEHICLE GRAVITY
(unload condition)
: JACK POSITION
±
INTRODUCTION REPAIR INSTRUCTION
01±19
AVENSIS REPAIR MANUAL (RM1018E)
VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP
(a) As a rule, the vehicle must be unloaded when jacking up. Never jack up o\
r lift up the vehicle loaded
with things of heavy weight.
(b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves. Place a balance weight so as to keep it from rolling,\
or hold the jacking support
location using the mission jack.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the instruction manual for a safety operation.
(b) Do not damage tires or wheels with a free wheel beam.
(c) Using a wheel stopper, fix the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in the flat place using a wheel stopper at all times.
(b) Use a safety stand with a rubber attachment, as shownin the illustration.
(c) Support the specified location with a jack and safety stand accurately.
(d) When jacking up the front wheels, release the parking
brake and place wheel stoppers only behind the rear
wheels. When jacking up the rear wheels, place wheel
stoppers only in front of the front wheels.
(e) Do not work or leave the vehicle supported only by a jack. Be sure to support the vehicle with a safety stand.
(f) When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of the wheels that contact ground.
(g) When jacking down the vehicle with its front wheels jacked up, release t\
he parking brake and place wheel stoppers only in front of the rear wheels. When jacking down the v\
ehicle with its rear wheels
jacked up, place wheel stoppers only behind the front wheels.
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D30400
Swing Arm Type Lift
Plate Type LiftCenter of Lift
: CENTER OF VEHICLE
GRAVITY (unloaded condition) Rubber Attachment
AttachmentBAL
Attachment Dimensions
85 mm (3.35 in.)
200 mm (7.87 in.)
100 mm (3.94 in.) 70 mm
(2.76 in.)
C
01±20
±
INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
4. NOTICE FOR USING SWING ARM TYPE LIFT
(a) Follow the instruction manual of the lift for a safe operation.
(b) Use a cradle with a rubber attachment, as shown in the illustration.
(c) Set in the vehicle so as to make its center of gravity as close as possible\
to the center of the lift. (ºLº becomes short.)
(d) Place the vehicle horizontally by adjusting the height of the cradle, and match th\
e groove of the cradle and the safety stand support location accurately.
(e) Be sure to lock the swing arm during the operation.
(f) Lift the vehicle up until the tires float, and shake the vehicle to make\
sure that the vehicle is stable.
5. NOTICE FOR USING PLATE TYPE LIFT
(a) Follow the instruction manual of the lift for a safe operation.
(b) Use a plate lift attachment.
(c) Be sure to set the vehicle to the specified position.
Right and left set position
Place the vehicle over the center of the lift.
Front and rear set position
Align the cushion gum ends of the plate with the attachment lower ends (\
A and C).

Align the attachment upper end (B) with the rocker flange front side n\
otch.
(d) Lift the vehicle up until the tires float a bit, and shake the vehicle t\
o make sure that the vehicle is stable.
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010B9±11
±
INTRODUCTION TERMS
01±37
AVENSIS REPAIR MANUAL (RM1018E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
Approx.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CANController Area Network
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
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010BA±14
01±42
±
INTRODUCTION TERMS
AVENSIS REPAIR MANUAL (RM1018E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this ma\
nual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI/INJ)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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022L4±02
02±36
±
PREPARATION AUTOMATIC TRANSMISSION / TRANS
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
07110±58060Air Conditioner Service Tool SetTRANSMISSION CONTROL CABLE
ASSY
(07117±58060)Refrigerant Drain Service ValveTRANSMISSION CONTROL CABLE
ASSY
(07117±58070)T±JointTRANSMISSION CONTROL CABLE
ASSY
(07117±58080)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±58090)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±78050)Refrigerant Charging GaugeTRANSMISSION CONTROL CABLE
ASSY
(07117±88060)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88070)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88080)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
09023±12700Union Nut Wrench 17mmAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09308±00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09316±60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U241E)
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022LX±01
±
PREPARATION DIAGNOSTICS
02±1
AVENSIS REPAIR MANUAL (RM1018E)
DIAGNOSTICS
PREPARATION
SST
09243±00020Idle Adjusting Screw WrenchSFI SYSTEM(1AZ±FE)
09843±18040Diagnosis Check Wire No.2AIR CONDITIONING SYSTEM
ELECTRONIC MOTOR POWER
STEERING SYSTEM
SUPPLEMENTAL RESTRAINT
SYSTEM
SFI SYSTEM(1AZ±FE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
09992±00242Turbocharger Pressure GaugeECD SYSTEM(1CD±FTV)
Recomended Tools
09082±00040TOYOTA Electrical TesterCOMBINATION METER
SFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FSE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U341E)
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