1999 TOYOTA AVENSIS heater

AC29V–02



I12508
DTC Check Harness
Current DisplayControl PanelPast Record DTC Display
In Normal
In Malfuction
”Heating”
Symbol
Memory Clear Button
DTC Calling ButtonDTC Calling Button
Connector BConnector A
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–9
COMBUSTION TYPE POWER HEATER
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 componects, etc.) and how to remedy are shown by connecting the DTC
tester and reading the DTC.
1. OPERATION
(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.






I12758
Buner Motor
Glow Plug
Overheating Sensor
Temp. Sensor
Flame SensorBR
B
BR
W
R
L R
L
BR
L
Connector B14
7 135
6 3 9
8 1
Power
Heater
ECUR
BR
B–R
G
G–W
L
Y
B–WConnector A 8
2
51
3
6
47R
BR
GTerminal L
of AlternatorBattery
Metering Pump
SWIG
Vehicle Side
14 13 10 9 825 13 647
11 1 2
12Fuse (20 A) B–R
G–W AC–10
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
2. DESCRIPTION OF DISPLAY AND BUTTONS
AF: Current Value Malfunction (Blinking at current failure)
Diag: DTC (Example: 064 Flame sensor break)
Mamory 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
The ECU is able to store up to 5 pieces of faulty memory. If it is full, the new data is written over F5.
4. WIRING DIAGRAM
Wire colors are indicated by an alphabetical code.
B=Black W=White BR=Brown L=Blue R=Red G=Green Y=Yellow
The first letter insicates the basic wire color and the seconk letter indicates the color of the stripe.

– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–11
5. ON–VEHICLE INSPECTION
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.
012OverheatingCheck temperature at temperature or overheating sensor >
125C.
Check water circuit.
014Possible overheating detected
(Hardware threshold value)Difference of measured values at temperature sensor > 15C
(min. 70C water temperature and metering pump in opera-
tion);
Check temperature sensor and overheating sensor, replace if
necessary.
017Overheating delected
(Hardware threshold value)Temperature at temperature or overheating sensor > 130C,
emergency OFF if DTC No. 012 or 014 not applicable;
Check water circuit, check temperature sensor and overheat-
ing sensor, 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 lead to combustion air motor (burner motor) for continu-
ity, replace if necessary.
032Combustion air blower motor short–circuitCheck combustion air blower motor (burner motor), replace if
necessary.
Check supply lead (chafed, etc.).
047Metering pump short–circuitCheck supply lead to metering pump for short–circuit, check
metering pump, replace if necessary.
048Metering pump breakCheck supply lead to metering pump for continuity, remedy
break, replace metering pump if necessary.
051Cold blow time exceededAt start, if flame sensor above 70C > 240 sec.;
Check exhaust gas combustion air supply, check flame sen-
sor, replace if necessary.
052Safety time exceededWhen all perm. start attempts used up;
Check fuel delivery and fuel supply.
Check exhaust gas and combustion air ducts.
054Flame cutout, HIGH settingCheck fuel delivery and fuel supply.
Check exhaust gas and combustion air ducts.
056Flame cutout, LOW setting
Check exhaust gas and combustion air ducts.
If combustion OK → Check flame sensor, replace if neces-
sary.
060Temperature sensor breakCheck connecting leads.
Resistance value between 6 and 13 at connector B > 2 MΩ
If break)
061Temperature sensor short–circuitCheck connecting leads.
Resistance value between 6 and 13 at connector B < 2 MΩ
(If short–circuit)

AC–12
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
DTC No.
Description of faultComment / Remedy
064Flame sensor breakCheck connecting leads.
Resistance value between 7 and 14 at connector B > 3,040 Ω
(If break)
065Flame sensor short–circuitCheck connecting leads.
Resistance value between 7 and 14 at connector B > 780 Ω
(If short–circuit)
071Overheating sensor breakCheck connecting leads.
Resistance value between 5 and 12 at connector B > 2MΩ
(If break)
072Overheating sensor short–circuitCheck connecting leads.
Resistance value between 5 and 12 at connector B < 50 Ω
(If short–circuit)
090
092
093Control unit detectice (Intermal fault / Reset)
Control unit detective (ROM error)
Control unit detective (RAM error)Control unit malfunction due to interference voltage from ve-
hicle electrical system;
Possible causes low batteries, chargers, other sources of
interlerence; eliminale interference voltages.
Internal faults detected in microprocessor / memory detected.
Replace control unit.
097Internal control unit faultsOther faults which cannot lead to DTC No.90, 92 and 93, re-
place control unit.

AC29W–02
I12467
Heater Hose (OUT)
Intake PipeFuel Line
Heater Connector Heater Hose (IN)
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–13
COMPONENTS

I12453
Cover JacketCover Blower
Control Unit and Cover Glow Plug
Flame SensorCable Harness
Electric Motor Complete
Heat Excharger
and JacketCombustion Chamber
with Flame Tube Water Temperature
Sensor Overheat Sensor
Plate
 Gasket  O–Ring
 Gasket
Control Unit and Cover Non–reusable part AC–14
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER

AC29X–01
I12474
I12475
I12476
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
AC–15
REMOVAL
1. REMOVE RH UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT HEATER HOSES
(a) Disconnect the inlet heater hose.
(b) Disconnect the outlet heater hose.
4. DISCONNECT FUEL LINE
Disconnect the fuel line from the fuel pump.
5. DISCONNECT FUEL PUMP CONNECTOR
6. DISCONNECT COMBUSTION TYPE POWER HEATER
CONNECTOR
7. REMOVE COMBUSTION TYPE POWER HEATER
Remove the 2 bolts holding the combustion type power heater
to the 2 brackets.

AC29Y–01
I12445
I12446
I12447
Control Unit
Cover
I12449
I12450
AC–16
– AIR CONDITIONINGCOMBUSTION TYPE POWER HEATER
DISASSEMBLY
1. REMOVE JACKET COVER
Remove the 4 screws and jacket cover.
2. REMOVE BLOWER COVER
Remove the 4 screws and blower cover.
3. REMOVE CONTROL UNIT AND COVER
(a) Remove the 2 screws.
(b) Remove the 2 hexagon screws.
(c) Remove the control unit and cover.
4. REMOVE CABLE HARNESS
(a) Remove the screw and plate.
(b) Remove the water temperature sensor and overheat sen-
sor.
5. REMOVE ELECTRIC MOTER
(a) Remove the 3 screws and the electric moter.
(b) Remove the gasket.