MOTOR TOYOTA AVENSIS 2005 Service Repair Manual

050TM±13
05±1100
±
DIAGNOSTICS AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
If the normal code is displayed during DTC check although the problem still occurs, check the circuits for
each problem symptom in the order given in the table below, and proceed to the relevant troubleshooting.
SymptomSuspect AreaSee page
Whole functions of the A/C system does not operate.
1. IG power source circuit
2. A/C amplifier assy
3. Engine ECU 1AZ±FSE: 1AZ±FE:
1ZZ±FE/3ZZ±FE:
1CD±FTV:05±1144
05±1098 05±294
05±149 05±5
05±528
Air Flow Control : No blower operation
1. Blower motor circuit
2. Heater relay circuit
3. Blower w/fan motor sub±assy
4. A/C amplifier assy05±1148
05±1146
05±1148
05±1098
Air Flow Control : No blower control1. Blower motor circuit05±1148
Air Flow Control : Insufficient air out
1. Blower w/fan motor sub±assy
2. Blower motor circuit
3. A/C amplifier assy05±1148
05±1148
05±1098
Temperature Control : Cool air does not come out
1. Volume of refrigerant
2. Drive belt tension
3. Refrigerant pressure
4. Air conditioner magnetic valve circut
5. Pressure sensor circuit
6. Air mix control servomotor circuit
7. Air mix damper position sensor circuit
8. Room temp. sensor circuit
9. Ambient temp. sensor circuit
10.A/C amplifier assy55±24
55±46
55±24
05±1151 05±1116
05±1133
05±1122
05±1102
05±1106
05±1098
Temperature Control : Warm air does not come out
1. Air mix control servomotor circuit
2. Air mix damper position sensor circuit
3. Ambient temp. sensor circuit
4. Room temp. sensor circuit
5. A/C amplifier assy
6. Heater radiator05±1133
05±1122
05±1106
05±1102
05±1098
±
Temperature Control : Output air is warmer or cooler than the set
temperature or response is slow.
1. Room temp. sensor circuit
2. Ambient temp. sensor circuit
3. Solar sensor circuit
4. Air mix damper position sensor circuit
5. Air mix control servomotor circuit
6. Evaporator temp. sensor circuit
7. A/C amplifier assy05±1102
05±110605±1113
05±1122
05±1133
05±1109
05±1098
Temperature Control : No temperature control (only Max. cool or Max. warm)
1. Room temp. sensor circuit
2. Ambient temp. sensor circuit
3. Solar sensor circuit
4. Air mix damper position sensor circuit
5. Air mix control servomotor circuit
6. Evaporator temp. sensor circuit
7. A/C amplifier assy05±1102
05±1106
05±1113
05±1122
05±1133
05±1109
05±1098
No air inlet control1. Recirculation damper servomotor circuit
2. A/C amplifier assy05±1153
05±1098
No air outlet control
1. Air outlet damper position sensor circuit
2. Air outlet control servomotor circuit
3. A/C amplifier assy05±1126
05±1136
05±1098

I35353
Recirculation Damper Servo Sub±assy
Mode Damper Servo Sub±assy
Evaporator Temp. Sensor
Evaporator
Airmix Damper Servo Sub±assy
Airmix No.2 Damper
Servo Sub±assy
Blower Motor ControlBlower w/ Fan Motor
Sub±assy
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1097
AVENSIS REPAIR MANUAL (RM1018E)

05C7W±01
05±1166
± DIAGNOSTICSCOMBUSTION TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
DIAGNOSTIC TROUBLE CODE CHART
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.
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 014 not is 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 conrol 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)

I35431
Buner Motor
Glow Plug
Surface Sensor
Temp.Control Sensor
Flame Sensor13
Power
Heater
ECU
Connector BTerminal L
of AlternatorBattery
Metering Pump
Fuse (20 A)
Vehicle Side SW 14
9
12
5
6
3
4
1
2BR
G
L±Y
L B±R
Y
L±WR
1
2
3
4 5
6
7
8W±B Connector A
IG
R±G
R±L (*1)
R±Y (*2)
R±B
W±R (*1)
Y±R (*2)
*1: TMC Made
*2: TMUK Made
± DIAGNOSTICSCOMBUSTION TYPE POWER HEATER SYSTEM
05±1165
AVENSIS REPAIR MANUAL (RM1018E)
2. DESCRIPTION OF DISPLAY AND BUTTONS
(a) AF: Current Value Malfunction (Blinking at current failure)
Diag: DTC (Example: 064 Flame sensor break)
Memory Clear button: Deletion of faulty memory (Press both buttons together for longer than 2 sec.)
> Button: Scroll up of faulty memory (The past 5 codes can be stored.)
< Button: Scroll down of faulty memory (The past 5 codes can be stored.)
3. FAULTY MEMORY
(a) The ECU is able to store upto 5 pieces of faulty memory. If it is full, the new data is written over F5.
4. WIRING DIAGRAM

I35396
R±W (*2) R±W (*2, *1) G±Y (*1)
W±B (*1)
W±B
(*1) R±W (*3, *1)
R±W (*3)
R±W (*2)CB1
CK 12 Center J/BP5
Power Heater SWA/C Control Assembly
A1611
J/C
J26H
J27F3IG
IN 6
E2
A
A J16
J/C
Driver Side J/B
DC6
From
HTR Fuse
ILHOTGASIN
*1: 1CD±FTV
*2: LHD
*3: RHD
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1159
AVENSIS REPAIR MANUAL (RM1018E)
HOT GAS HEATER SWITCH CIRCUIT
CIRCUIT DESCRIPTION
Hot gas heater performs only when its switch turns to ON and fulfill the following 6 conditions.

Hot gas heater switch is ON.

Recirculation damper position is FRS.

Blower motor switch is in the position other than OFF.

Ambient temperature varies according to the following condition;
A/C switch ONBelow ±1.5C (32F)
A/C switch OFFBelow 8C (46F)

Air mix damper position is MAX HOT.

Water temperature is 70C (158F) or less.
WIRING DIAGRAM
05C7S±01

I35380
R±W
(*2)J26 J26HH
IE111
IE218
A157
MGV A/C Control Assembly
R±W
(*2)R±W R±B R±Y J/CC4
Condenser
Assembly
12
Driver Side J/B
DC6
DB5
R±W
(*1)
From
HTR Fuse
*1: LHD
*2: RHD
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1157
AVENSIS REPAIR MANUAL (RM1018E)
HOT GAS HEATER MAGNETIC VALVE CIRCUIT
CIRCUIT DESCRIPTION
For the hot gas heater, it is necessary to fulfill the following 6 conditions.

Hot gas heater switch is ON.

Recirculation damper position is FRS.

Blower motor switch is in the position other than OFF.

Ambient temperature varies according to the following condition;
A/C switch ONBelow ±1.5C (32F)
A/C switch OFFBelow 8C (46F)

Air mix damper position is MAX HOT.

Water temperature is 70C (158F) or less.
WIRING DIAGRAM
05C7R±01

I35397
R±W (*1)1
CB A15 RECR±Y A21
Air Inlet Control
Servo Motor
5 A/C Control Assembly
3 Center J/B
Driver Side J/B
From
HTR Fuse J266
CER±W (*1)
+
1
R±W (*2)
A15 FRS P±B6
R±W (*2)
J26 HHJ/C
2
R±W (*2)
R±W (*2)
DC6
*1: LHD
*2: RHD
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1153
AVENSIS REPAIR MANUAL (RM1018E)
RECIRCULATION DAMPER SERVOMOTOR CIRCUIT
CIRCUIT DESCRIPTION
The recirculation damper servomotor is controlled by the A/C amplifier and moves the air inlet damper to the
desired position.
WIRING DIAGRAM
05C7Q±01

I36092
LHD Models:
FRSREC
I36094
I36093
RHD Models:
FRS
REC
I36094
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1155
AVENSIS REPAIR MANUAL (RM1018E)
2 INSPECT RECIRCULATION DAMPER SERVO SUB±ASSY
(a) Remove the recirculation damper servo sub±assy.
(b) Connect the positive (+) lead to from the battery to termi-
nal 3 and negative (±) lead to terminal 2, then check that
the arm turns to ºFRSº side smoothly.
(c) Connect the positive (+) lead to from the battery to termi-
nal 3 and negative (±) lead to terminal 1, then check that
the arm turns to ºRECº side smoothly.
If operattions are not as specified, replace the mode damper
servomotor.
NG REPLACE RECIRCULATION DAMPER SERVO
SUB±ASSY
OK

I36148
Duty Ratio =A + BA
x 100 (%)
ON 0 VOFF 5 VA
1 cycle Blower Level (Reference)
Si duty (%)
B HI
M8
M7
M6
M5
M4
M3
M2
M1
LO
26.3
30.937.8
44.751.6
58.465.3
74.583.7 100.0
I36133
B5
Blower Motor
Controller
A/C Control Assembly
SI
+B
VM
GND2
3
4
1LB
M
2
1 L±BL±BR
Driver Side J/B
DF2From
HTR
RELAY
L±B
J15
J/C A
IK5
A16 BLW L±B
2
IJ2
1
IJ2
4
IJ2 B±WB
W±B 3
IJ2
B4
Blower Motor
W±B 05±1148
± DIAGNOSTICSAIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
BLOWER MOTOR CIRCUIT
CIRCUIT DESCRIPTION
The blower motor is operated by signals from the A/C amplifier. Blower motor speed signals are transmitted
by changes in the Duty Ratio.
Duty Ratio
The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity
in one cycle, and then B is the period of non±continuity.
WIRING DIAGRAM
05C7O±01

I30151
2
1
LHD
RHD
±
DIAGNOSTICS AIR CONDITIONING SYSTEM
05±1149
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
1PERFORM ACTUATOR CHECK
(a)Set to actuator check mode (See page 05±1091).
(b)Press the DEF switch and change to step operation.
(c)Check the air flow level by hand.
Display CodeBlower level
00
11
216
316
416
516
616
716
816
931
OKPROCEED TO NEXT CIRCUIT INSPECTION
SHOWN ON PROBLEM SYMPTOMS TABLE
NG
2INSPECT BLOWER W/FAN MOTOR SUB±ASSY
(a)Connect the positive (+) lead from the battery to terminal 1 and negative (±) to terminal 2.
Standard: Blower motor operates smoothly.
If operation is not as specified, replace the blower motor.
NGREPLACE BLOWER W/FAN MOTOR SUB±ASSY
OK
3CHECK HARNESS AND CONNECTOR(BLOWER W/FAN MOTOR SUB±ASSY ± BLOWER MOTOR CONTROL)
(a)Check for an open or short circuit in harness and connector between blow\
er w/fan motor sub±assy
and blower motor control (See page 01±32).
NG REPAIR OR REPLACE HARNESS ORCONNECTOR
OK