MOTOR TOYOTA AVENSIS 2005 Service Manual PDF

C52361
DLC3:
CGTs 05±1050
± DIAGNOSTICSELECTRONIC MOTOR POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(5) Disconnect and connect the terminal Tc of DLC3 20
times within 20 seconds.
(6) Check the DTC C1515/15 output.
(c) Perform the torque sensor zero point calibration.
HINT:

Do not touch the steering wheel.

Check that the DTC for except C1515/15 is not output.
(1) Stop the vehicle and turn the ignition switch to OFF.
(2) Using SST, connect terminals Ts and CG of DLC3
and turn the ignition switch to ON.
SST 09843±18040
(3) Disconnect the SST.
SST 09843±18040
(4) Check the DTC is not output.
8. CALIBRATION OF TORQUE SENSOR ZERO POINT
(USING HAND±HELD TESTER)
HINT:
Perform this operation in the following cases.

When removing and installing ºsteering wheel assemblyº,
ºtilt steering column assemblyº and ºsteering gear assem-
blyº.

When replacing power steering ECU assy.
(a) Place front wheels and steering wheel facing straight
ahead.
(b) Perform the torque sensor zero point initialization.
HINT:
If the power steering ECU assy is replaced, initialization is not
necessary.
(1) Stop the vehicle.
(2) Connect the hand±held tester to the DLC3.
(3) Select the ºTRQ SENS ADJUSTº mode on the
hand±held tester.
(4) Select the ºZERO POINT INITIALIZEº.
(5) Following the screen instructions, perform the
torque sensor zero point initialization.
(c) Perform the torque sensor zero point calibration.
HINT:
Do not touch the steering wheel.
(1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) Select the ºTRQ SENS ADJUSTº mode on the
hand±held tester.
(4) Select the ºZERO POINT ADJUSTº.
(5) Following the screen instructions, perform the
torque sensor zero point calibration.

±
DIAGNOSTICS ELECTRONIC MOTOR POWER STEERING SYSTEM
05±1051
AVENSIS REPAIR MANUAL (RM1018E)
9.REPLACE POWER STEERING ECU ASSY
NOTICE:
Thoroughly check the procedures for removing and instal-
ling the power steering ECU assy when replacing it. Do the
same operation or procedure for the removing and instal-
ling the steering column assy.
(a)Remove the power steering ECU assy (See page
50±20).
(1) Mark the clamp position on the torque sensor wireharness in order to reinstall the wire harness as
shown in the illustration.
(2) Disconnect the torque sensor wire harness from the
clamp.
NOTICE:
In case the clamp will be reused, pay attention so as not to
damage it. (3) Disconnect the connectors.
(4) LHD:Remove the 2 bolts, screw and power steering ECU
assy.
(5) RHD: Remove the 2 bolts, 2 screws and power steering
ECU assy.

F44857
LHD:RHD:
Torque Sensor Wire Harness Clamp
Marks
Power Steering ECU Assy
Front
Motor Wire Harness
Torque Sensor
Wire Harness
Front
Torque Sensor
Wire Harness
Motor Wire Harness
Power Steering ECU Assy
Torque Sensor Wire Harness Clamp
Marks
Screw
Bolt A
Bolt A
Bolt B
Bolt B
Screw
05±1052
±
DIAGNOSTICS ELECTRONIC MOTOR POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the power steering ECU assy (See page 50±20).
(1) LHD:Install the power steering ECU assy with the 2 bolts
and screw.
Torque:
Bolt A: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
Bolt B: 15.5 N
m (158 kgf
cm, 11 ft
lbf)
(2) RHD: Install the power steering ECU assy with the 2 bolts
and 2 screws.
Torque:
Bolt A: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
Bolt B: 15.5 N
m (158 kgf
cm, 11 ft
lbf)
(3) Connect the connectors.

± DIAGNOSTICSELECTRONIC MOTOR POWER STEERING SYSTEM
05±1053
AVENSIS REPAIR MANUAL (RM1018E)
(4) Align the marks on the torque sensor wire harness
with the clamp, as shown in the illustration.
NOTICE:

When reusing the clamp, check that there is no dam-
age on it.

When reinstalling the wire harness, make sure there
is no twist in the harness or with other wire harness.
10. FAIL SAFE FUNCTION
(a) If the power steering ECU assy detects a trouble, the ECU
assy halt, fix or lower the steering power assist in order to
protect the system.
HINT:
Repeating the steering operation when stopping or driving at
low speed, or leaving the steering wheel turn fully for long hours
will lower the amount of power assist in order to prevent power
steering ECU assy from heating up. In this case, not operating
the steering for about 10 minutes with engine idle will lead the
fail safe function to return the normal state.

050Y7±04
Inspector 's
Name:
Customer 's Name
Date Vehicle
Brought InLicence No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs
ContinuousIntermittent ( times a day)
Steering operation is heavy.
Steering force to the right and left differs, or steering force is uneven.
PS Warning Light
AbnormalRemains ONDoes not come on
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles
EMPS Check Sheet
While running, the steering force does not alter corresponding the vehicle
speed.
Vibration or strange sound comes from the steering column assy.
A malfunction code is outputed at the first time, record the freeze frame data as well (as the DTCs). Freeze Frame Data
When a trouble happens
(
During turningDuring vehicle stopAlways)
OthersCooled Warmed up
/ /Engine() Vehicle Model
The steering returns unwell.
Production Date VIN 05±1044
± DIAGNOSTICSELECTRONIC MOTOR POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
CUSTOMER PROBLEM ANALYSIS CHECK

050Y2±04
05±1042
±
DIAGNOSTICS ELECTRONIC MOTOR POWER STEERING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ELECTRONIC MOTOR POWER STEERING SYSTEM
HOW TO PROCEED WITH TROUBLESHOOTING
Perform troubleshooting in accordance with the procedure on the following pages\
.
HINT:

See the indicated pages for detailed explanation.

The hand±held tester can be used at step 3, 6, 9, 12.
1VEHICLE BROUGHT TO WORKSHOP
2CUSTOMER PROBLEM ANALYSIS(See page 05±1044)
3 CHECK AND CLEAR DTCS AND FREEZE FRAME DATA
(a)After the completion of the DTC and freeze frame data check, clear the DTCs (See page 05±1045).
4 PROBLEM SYMPTOM CONFIRMATION
SYMPTOM DOES NOT OCCUR(Go to step 5)
SYMPTOM OCCURS(Go to step 6)
5SYMPTOM SIMULATION(See page 01±22)
6DTC CHECK(See page 05±1045)
NORMAL CODE(Go to step 7)
MALFUNCTION CODE(Go to step 8)
7PROBLEM SYMPTOMS TABLE(See page 05±1058)
8DTC CHART(See page 05±1054)

050TJ±13
05±1094
±
DIAGNOSTICS AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
DIAGNOSTIC TROUBLE CODE CHART
If malfunction code is displayed during the DTC check (sensor check), ch\
eck the circuit listed for the code
in the table below (Proceed to the page given for that circuit).
DTC No.
(See Page)Detection ItemTrouble AreaMemory
00Normal±±
11 *1
(05±1102)
Room temperature sensor circuit
(open/short)
Cooler thermistor (room temp. sensor)

Harness or connector between cooler thermistor (room
temp. sensor) and A/C amplifier assy

A/C amplifier assy

(8.5 min. or more)
12 *2
Ambient temperature sensor circuit
(open/short)
Thermistor assy (ambient temp. sensor)

Harness or connector between thermistor assy (ambient
temp. sensor) and combination meter

Combination meter12
(05±1106)
Combination meter

Harness or connector between combination meter and A/C
amplifier assy

A/C amplifier assy
(8.5 min. or more)
13
(05±1109)
Evaporator temperature sensor circuit
(open/short)
Cooler thermistor No.1 (evaporator temp. sensor)

Harness or connector between cooler thermistor No.1
(evaporator temp. sensor) and A/C amplifier assy

A/C amplifier assy

(8.5 min. or more)
21 *3
Solar sensor circuit (open) (Passenger
side)
Automatic light control sensor (solar sensor)

Harness or connector between automatic light control sen-
( l ) d A/C lifi

(8.5 min. or more)
21
(05±1113)
Solar sensor circuit (short) (Passenger
side)sor (solar sensor) and A/C amplifier assy

A/C amplifier assy
±
23
(05±1116)
Pressure sensor circuit
A/C tube assy (pressure sensor)

Harness or connector between A/C tube assy (pressure
sensor) and A/C amplifier assy

A/C amplifier assy
±
24 *3
Solar sensor circuit (open)
(Driver side)
Automatic light control sensor (solar sensor)

Harness or connector between automatic light control sen-
( l ) d A/C lifi

(8.5 min. or more)
24
(05±1119)
Solar sensor circuit (short)
(Driver side)sor (solar sensor) and A/C amplifier assy

A/C amplifier assy
±
31
(05±1122)
Air mix damper position sensor circuit
(Passenger side)
Air mix damper servo sub±assy (air mix damper position
sensor)

Harness or connector between air mix damper servo sub±
assy (air mix damper position sensor) and A/C amplifier
assy

A/C amplifier assy

(1 min. or more)
33
(05±1126)
Air outlet damper position sensor circuit
Mode damper servo sub±assy (mode damper position sen-
sor)

Harness or connector between mode damper servo sub±
assy (mode damper position sensor) and A/C amplifier assy

A/C amplifier assy

(1 min. or more)
36
(05±1129)
Air mix damper position sensor circuit
(Driver side)
Air mix damper servo sub±assy (Air mix damper position
sensor)

Harness or connector between air mix damper servo sub±
assy (air mix damper position sensor) and A/C amplifier
assy

A/C amplifier assy

(1 min. or more)
41
(05±1133)
Air mix damper control servomotor
(Passenger side)
Air mix damper servo sub±assy (air mix damper control)

Harness or connector between air mix damper servo sub±
assy (air mix damper control) and A/C amplifier assy

A/C amplifier assy

(15 sec.)

±
DIAGNOSTICS AIR CONDITIONING SYSTEM
05±1095
AVENSIS REPAIR MANUAL (RM1018E)43
(05±1136)
Air outlet damper control servomotor
Mode damper servo sub±assy (mode damper control)

Harness or connector between mode damper servo sub±
assy (mode damper control) and A/C amplifier assy

A/C amplifier assy

(15 sec.)
46
(05±1139)
Air mix damper control servomotor
(Driver side)
Air mix damper servo sub±assy (air mix damper control )

Harness or connector between air mix damper servo sub±
assy (air mix damper control servomotor) and A/C amplifier

A/C amplifier assy

(15 sec.)
HINT:

*1: If the room temp. is approx. ±18.6
C (±3.7
F) or lower, DTC 11 may be output even though the sys-
tem is normal.

*2: If the ambient temp. is approx. ±52.9
C (±61.4
F) or lower, DTC may be output even though the
system is normal.

*3: If the check is being performed in a dark place, DTC 21 and 24 (solar \
sensor circuit abnormal) could
be displayed.

I36146
Display code R/FDEFLHD:
I36147
Display code RHD:R/FDEF
Blower level Step No.Display
codeConditions
Air flow bent Air inlet damper Compressor
ºCOOLº side (Full closed)Air mix damper
OFF FRESH
FACE 0
1
2
3
6
7
8
9
104
51
16
16
16
16
16
16
16
31 0
1
2
3
6
7
8 4
5
9FACE
FACE
FACE
B/L
FOOT1
FOOT/ DEF.
DEF.FRESH
ON
ON
ON
ON
ON
ON
ONºCOOLº side (Full closed)
ºCOOLº side (Full closed)
ºCOOLº side (Full closed)
ºCOOLº/ ºHOT º (50 % open)
ºHOTº side (Full opened)
FOOT FACE1FRESH
FRESH
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATIONHot gas magnetic valve
ºCOOLº/ ºHOT º (50 % open)
ºHOTº side (Full opened)
ºHOTº side (Full opened)ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF OFF
ºHOTº side (Full opened) OFF
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1093
AVENSIS REPAIR MANUAL (RM1018E)
6. ACTUATOR CHECK
(a) After entering the DTC check mode (Sensor Check
Mode) press the R/F switch.
(b) Since each damper, motor and relay automatically oper-
ates at 1 second intervals beginning in order from 10 in
the temperature display, check the temperature and air
flow from visual and by hand.
If the slower display is desired, press the DEF switch and
change it to step operation. Each time the DEF switch is
pressed, the display changes by 1 step.
HINT:

Codes are displayed from the smaller to the larger num-
bers in order.

To cancel the check mode, press the OFF switch.

050TH±09
I30150
Inspector 's name:
Customer 's NameVIN
Production Date
Licence No.
Odometer Readingkm
Miles Date vehicle
Brought In / /
Date of Problem Occurrence
How Often does Problem Occur?
Weather
Outdoor Temperature / /

Continuous
Intermittent ( times a day)

Fine
Cloudy
Snowy
Various / Other

Hot
Warm
Cool
Cold (Approx.
F

C)
Symptoms
Blower motor does not operate

Blower motor speed does not change
(Always Hi, Always Mid, Always Lo) Air Flow Control
Faulty

Cabin temperature does not go down

Response is slow

Cannot change between FRS and REC
(Always Fresh or always Recirculating)

Will not enter the desired mode Temperature
Control Faulty
Air Inlet Control
Faulty
Vent Control
Faulty
DTC Check1st Time
2nd Time
Normal Code
Malfunction Code (Code )

Normal Code
Malfunction Code (Code )
AIR CONDITIONING SYSTEM Check Sheet

Cabin temperature does not rise

Mode will not change 05±1090
± DIAGNOSTICSAIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
CUSTOMER PROBLEM ANALYSIS CHECK