air condition TOYOTA AVENSIS 2003 Service Repair Manual

NEW MODEL OUTLINE


\b


\b
Manual Air Conditioner Control Panel
for LHD model Automatic Air Conditioner Control Panel
for LHD model


\b
Automatic Air Conditioner Control Panel
Driver Side
Temperature Front Passenger
Side Temperature
When BI-level Mode
Warm Air
Cold Air


\b
Air warmed by the evaporator
Heat released by the evaporator
Blower Air Heater Core
Compressor
Hot Gas Tank
Magnet Valve Refrigerant
Aaccumulator Tank
Condenserr Expansion Valve
MO-20
Air Conditioner System

A manual air conditioner is standard equipment on ENTRY grade models and an automatic
air conditioner on MID TECHNICAL and MID ELEGANT grade models.

The automatic air conditioner employs a left / right independent temperature control system.
Power Heater System

1CD-FTV engine models feature three power heater systems: PTC, hot-gas, \
and combustion.

The hot-gas heater was newly developed to enhance the heater performance\
of the diesel
engine.

The hot-gas heater features an orifice, magnetic valve, and hot-gas tank\
added to the air
conditioner components. Refrigerant raised to a high temperature and pressure by th\
e
compressor is guided to the evaporator and the heat is released.
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MO
NEW MODEL OUTLINEMO-29


: Standard OP: Option
EuropeGeneral
ENTRYMID
TECHNICALMID
ELEGANTGeneralCountries
Body Electrical
HeadlightProjector



HeadlightHID (High lntensity Discharge)ÐOPOPÐ
Headlight BeamManual


Ð
Level Control SystemAutomaticÐOPOPÐ
Headlight Cleaner SystemOP*5OPOPÐ
FrontExcept for 1AZ-FEOP

Ð
Fog LightFront1AZ-FEÐOPOPOP*4
Rear


Ð
Illuminated Entry System




Navigation SystemÐOPOPÐ
Multi information DisplayOP

Ð
8-speaker OnlyOPOPOPOP
Audio SystemRadio / CD / Cassette / 8-speaker




Steering Switch


Ð
Manual
ÐÐ

Air ConditionerAutomaticÐ

Ð
WithoutOPÐÐOP
Conventional TypeExcept for 1CD-FTV




HeaterPTC Type1CD-FTVOPÐÐÐHeaterHot Gas Type1CD-FTV


Ð
Combustion TypeLHD of 1CD-FTVÐOPOPÐ
WiperFrontAdjustment Interval INT Function
ÐÐ
Wiper
SystemFrontRaindrop Sensing FunctionÐ

ÐSystemRearIntermittent FunctionLiftback & Wagon


Ð
Power Window
Front Door One-Motion Auto Up-and-Down,
Jam Protection Function
ÐÐ

SystemAll-Door One-Motion Auto Up-and-Down,
Jam Protection FunctionOP

OP
Door Lock ControlPower Door Look Control System



Door Lock Control
SystemWireless Door Look Remote Control System


ÐSystemDouble Locking SystemExcept for 1AZ-FE & LHD


Ð
Engine ImmobiliserExcept for 1AZ-FE



System1AZ-FEÐOPOPÐ
Theft Deterrent SystemExcept for 1AZ-FE & 1CD-FTV


Ð
5
Driver & Front Passenger & SideExcept for 1AZ-FEOPÐÐÐ
SRS*5 Airbag& Knee Airbags1AZ-FEÐ



SystemDriver & Front Passenger & SideExcept for 1AZ-FE



& Knee & Curtain Shield Airbags1AZ-FEÐOPOPÐ
Cruise Control System1AZ-FSE & 1CD-FTVÐOPOPÐ
Outside RearElectrical Retractable with HeaterÐ

Ð
View MirrorElectrical RetractableÐÐÐ

Inside RearAutomatic Glare-Resistant EC (Electrical) TypeÐ

Ð
View MirrorManual Glare-Resistant Type
ÐÐ

Power Tilt Up-and-Sliding Moon RoofExcept for 1AZ-FSEOPOPOPÐ
(with Jam Protection Function)1AZ-FSEÐOP*6OP*6Ð
*4: LHD Models
*5: Supplemental Restraint System
*6: Except for Automatic Transaxle of Wagon Models
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010B8±08
D25086
WRONGCORRECT
D25087
Looseness of CrimpingCore Wire Terminal
Deformation
Pull Lightly
01±32
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
ELECTRONIC CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS (1) Unless stated, all resistance is measured at an ambient temperature of 20 C (68 F). As the re-
sistance may be outside the specifications if measured at high temperatures imme\
diately after
the vehicle has been running, measurements should be made when the engine h\
as cooled
down.
(b) HANDLING OF CONNECTOR(1) When removing the connector with lock, press the
connector in the direction of the engagement and
remove the lock by lightly pressing the lock claw.
(2) When removing the connector, do not hold the har- ness, but hold the connector.
(3) Before connecting the connector, check that there is no deformation, damage or missing terminals.
(4) The connector with a lock should be securely con- nected until it makes a ºclickº sound.
(5) When checking the connector with a Toyota electri- cal tester, check it from the backside (harness side)
of the connector using a mini test lead.
NOTICE:

As a water proof connector cannot be checked from
the backside, check by connecting the sub±harness.

Do not damage the terminals by moving the inserted
tester needle.
(c) CONNECTOR CHECKING POINTS
(1) Checking when the connector is connected:By holding the connector, check the inserted condi-
tion and locking efficiency (engaged condition).
(2) Checking when the connector is removed: Check by lightly pulling the wire harness (missing
terminal, terminal crimping condition, core wire
break).
Check visually for any rust, metal particles, water
and bent terminals (rust, mixing of foreign object,
terminal deformation).
NOTICE:
When testing a gold±plated female terminal, always use a
gold±plated male terminal.
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D25088
Same terminal as
a male terminal
D20024
WRONG
CORRECT
D01557
WRONG
Z17004
C
SensorOPEN
1 2 B
1
2 1
2 1
2A
Fig. 1
ECU
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±33
AVENSIS REPAIR MANUAL (RM1018E)
(3) Checking of the contact pressure of the terminal:
Prepare a spare male terminal.
Insert it into a female terminal, check the engaged
condition and sliding resistance.
(d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is on the contact point, clean the contact
point using an air gun or shop rag. However, never
polish the contact point using sand paper as the
platings may come off.
(2) In case of abnormal contact pressure, replace the
female terminal. However, if a male terminal is gold±
plated (gold color), use gold±plated female terminal
and if it is silver±plated (silver color), use silver±
plated female terminal.
(e) HANDLING OF WIRE HARNESS (1) When removing the wire harness, check the posi-tioning of the wiring and clamping before starting
work in order to be able to restore it correctly.
(2) Never twist, pull or loosen the wire harness more
than necessary.
(3) Never allow the wire harness to come into contact with a high±temperature, rotating, moving, vibrating
or sharp (edge of the panel, tip of the screw, etc.)
part.
(4) When installing parts, never let the wire harness be interfered with.
(5) Never cut or break the cover of the wire harness. If one is cut or broken, replace it or securely repair it
with electrical tape.
2. CHECK OPEN CIRCUIT
(a) For the open circuit in the wire harness in Fig. 1, perform a continuity check in step (b) or a voltage check in step (c)
to locate the section.
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IN0383
ExampleGround
IN0384
Ground
ECU Side
W/H Side
Ground
01±36±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
4. CHECK AND REPLACE ECU
NOTICE:

Start an inspection of the connector from the back-
side of the connector on the wire harness side with
the connector connected to the ECU.

When no measurement condition is specified, per-
form the inspection with the engine stopped and also
the ignition switch ON.
(a) First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. In this case, re-
place the ECU with one that functions normally and check
if the symptoms appear.
(1) Measure the resistance between the ECU groundterminal and body ground.
Resistance: 1
or less
(2) Disconnect the ECU connector, check the ground terminals on the ECU side and wire harness side for
bends and check the contact pressure.
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010B6±13
±
INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±21
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
There are many ECU controlled systems used in the AVENSIS. In general, ECU controlled system are con-
sidered to be very intricate and require a high level of technical knowledge an\
d expert skill to troubleshoot.
The fact is, however, that if you proceed by inspecting the circuits one by one, troubleshoo\
ting of these sys-
tems is not complex. If you have adequate understanding of the system and ba\
sic knowledge of electricity,
the problem can be accurately diagnosed and fixed. This manual is design\
ed based on the above principle
to help service technicians perform accurate and effective troubleshooting, and is compiled for the following
major ECU controlled systems:
The troubleshooting procedures are described on the following pages.
SystemPage
1. SFI System [1ZZ±FE, 3ZZ±FE]05±1
2. SFI System [1AZ±FE]05±143
3. SFI System [1AZ±FSE]05±290
4. ECD System [1CD±FTV]05±523
5. ABS with EBD System05±696
6. ABS with EBD & BA & TRC & VSC System05±752
7. Electronic Controlled Automatic Transmission [ECT] [U241 (1AZ±FE)]05±856
8. Electronic Controlled Automatic Transmission [ECT] [U241 (1AZ±FSE)]05±915
9. Electronic Controlled Automatic Transmission [ECT] [U341]05±980
10.Electronic Motor Power Steering System05±1042
11. Air Conditioning System05±1088
12.Combustion Type Power Heater System05±1161
13.Supplemental Restraint System05±1181
14.Audio System05±1393
15.Navigation System05±1435
16.Combination Meter05±1497
17.Power Door Lock Control System05±1534
18.Wireless Door Lock Control System05±1568
19.Key Reminder Warning System05±1586
20.Engine Immobiliser System05±1599
21.Theft Deterrent System05±1627
22.Multiplex Communication System05±1654
23.Cruise Control System05±1697
FOR USING HAND±HELD TESTER

Before using the tester, the tester's operator manual should be read thoroughly.

If the tester cannot communicate with the ECU controlled systems when you \
have connected the cable
of tester to the DLC3, turned the ignition switch ON and operated the test\
er, there is a problem on the
vehicle side or tester side.
(1) If the communication is normal when the tester is connected to another veh\
icle, inspect the diag-
nosis data link line (Bus
line) or ECU power circuit of the vehicle.
(2) If the communication is still impossible when the tester is connected to a\
nother vehicle, the prob- lem is probably in the tester itself, so perform the Self Test procedures outlined in the Tester Oper-
ator 's Manual.
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010B7±13
01±22±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
Carry out troubleshooting in accordance with the procedures on the follo\
wing page. Here, only the basic
procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods
for each circuit. Confirm the troubleshooting procedures first for the r\
elevant circuit before beginning trouble-
shooting of that circuit.
1 Vehicle brought to workshop
2 Customer problem analysis
(a) Ask the customer about the conditions and environment when the problem o\
ccurred.
3 Symptom confirmation and DTC (and freeze frame data) check
(a) Check the battery positive voltage. Voltage: 11 ± 14 V (Engine stopped)
(b) Visually check the wire harness, connectors and fuses for open and short,\
etc.
(c) Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions, and check for DTCs accordin\
g to the related chart.
OK Go to step 5
NG
4 DTC chart
(a) Check the results obtained in step 3, then confirm the inspection procedures \
for the system or the part which should be checked using the DTC chart.
Go to step 6
5 Problem symptoms chart
(a) Check the results obtained in step 3, then confirm the inspection procedures \
for the system or the partwhich should be checked using the problem symptoms table.
6 Circuit inspection or parts inspection
(a) Confirm the circuit for the system or the part which should be checked u\
sing the problem symptoms
table or the results obtained in step 4.
7 Repair
(a) Repair the affected system or part in accordance with the instructions in step 6.
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±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±23
AVENSIS REPAIR MANUAL (RM1018E)
8 Confirmation test
(a) After completing repairs, confirm that the problem has been solved (If the p\
roblem does not recur, per-
form a confirmation test under the same conditions and in the same environment as when it occurred
for the first time).
END
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Important Points with Customer Problem Analysis

What ±±±±± Vehicle model, system name

When ±±±±± Date, time, occurrence frequency

Where ±±±±± Road conditions

Under what conditions? ±±±±± Running conditions, driving\
conditions, weather conditions

How did it happen? ±±±±± Problem symptoms
(Sample) Supplemental restraint system check sheet.
Supplemental Restraint System Check Sheet
Customer's Name
Date Vehicle Brought In
Registration No.
Frame No.
Odometer Reading
km
miles
Date Problem First Occurred
Weather
Temperature
Vehicle OperationFine Cloudy
StartingIdling
Driving
Constant speed Acceleration
OtherInspector's
Name
CUSTOMER PROBLEM ANALYSIS CHECK
Registration Year
RainySnowyOther
/ /
/ /
/ /
Approx.
Deceleration
[
]
01±24±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
CUSTOMER PROBLEM ANALYSIS
HINT:
In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all preconcep-
tions must be set aside in order to make an accurate judgement. To ascertain what the problem symp-
toms are, it is extremely important to ask the customer about the problem an\
d conditions when it oc-
curred.
The following 5 items are important points in the problem analysis. Past\
problems which are thought
to be unrelated and the repair history, etc. may also help in some cases. Therefore, as much informa-
tion as possible should be gathered and its relationship with the problem symptoms should be correctly
ascertained for use as reference in troubleshooting. A customer problem analysis ta\
ble is provided for
your use in the Diagnostics Section for each system.
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±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±25
AVENSIS REPAIR MANUAL (RM1018E)
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT:

The diagnostic system in AVENSIS has various functions. The first function is the Diagnostic Trouble
Code (DTC) Check, in which a malfunction in the signal circuits to the ECU is stored in code form in
the ECU memory. Another function is the Input Signal Check, which checks if the signals from various
switches are sent to the ECU correctly. By using these check functions, it is possible to quickly narrow
down potential problem areas and troubleshooting can be performed effectively. The diagnostic func-
tions are incorporated in the following systems in the AVENSIS.
SystemDiagnostic Trouble
Code CheckInput Signal Check(Sensor Check)Diagnostic Test
Mode (Active Test)
SFI System (1AZ±FE/1AZ±FSE, 1ZZ±FE/3ZZ±FE)

(with Check Mode)


ECD System (1CD±FTV)

(with Check Mode)


ABS with EBD System



ABS with EBD & BA & TRC & VSC System



Electronically Controlled Automatic Transmission [ECT]

(with Check Mode)

Air Conditioning System


Supplemental Restraint System

Audio System

Power Door Lock Control System


Wireless Door Lock Control System

Key Reminder Warning System

Engine Immobiliser System


Theft Deterrent System


Multiplex Communication System

Cruise Control System



In the DTC check, it is very important to determine whether the problem indicated by the DTC is still
occurring or has occurred in the past but returned to normal at present. In addit\
ion during the problem
symptom check, it a check must be made on whether the malfunction indicated by \
the DTC is directly
related to the problem symptom or not. For this reason, the DTC should be checked before and after
symptom confirmation to determine the current conditions. If this is not done, \
it may, depending on the
case, result in unnecessary troubleshooting for systems that are operati\
ng normally. This would make
more difficult to detect the problem area or to try to repair irrelevant areas. \
Therefore, always follow
the procedures in the correct order and perform the DTC check.

A flow chart showing how to proceed with troubleshooting using the diagnostic trouble\
code (DTC)
check is shown the this page. This flow chart shows how to utilize the DTC check effectively. Then,
by carefully checking the results, this chart indicates how to proceed either to the DTC troubleshooting
or to the troubleshooting of the problem symptoms table.
1 DTC check
2 Make a note of DTCs displayed and then clear the memory
3 Symptom confirmation
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