2002 TOYOTA AVENSIS Repair Manual

550ZG±01



I12508
Connector B
DTC Check Harness
Current DisplayControl PanelPast Record DTC Display
Memory Clear Button
DTC Calling Button
DTC Calling ButtonºHeatingº
Symbol In Normal
In Malfunction Connector A
± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
55±15
AVENSIS REPAIR MANUAL (RM1018E)
COMBUSTION TYPE POWER HEATER SYSTEM
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 components, etc.) and repair methods are shown by connecting the DTC
tester and reading the DTC.
1. DIAGNOSTICS FUNCTION
(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.

I35431
Burner 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
2R
BR
B±R
G
L±Y
L
Y
L±W5
1
6
2
7
3
8
4W±B
R±G
R±B Connector A
IG
W±R (*1)
Y±R (*2)
R±L (*1)
R±Y (*2)
*1: TMC Made
*2: TMUK Made 55±16
± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
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 se-
conds)
> 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 up to 5 pieces of faulty memory. If it is full, the new data is written over F5.
4. WIRING DIAGRAM

± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
55±17
AVENSIS REPAIR MANUAL (RM1018E)
5. DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit listed for the 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 014s not 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 control 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)

55±18
± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)DTC No.Comment / Remedy Description of fault
071Surface sensor break
Check connecting leads.
Resistance value between 4 and 11 at connector B > 2
 (If
break)
072Surface sensor short±circuit
Check connecting leads.
Resistance value between 4 and 11 at connector B > 50  (If
short±circuit)
090
092
093Control unit detective (Internal 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
interference; eliminate 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,
replace control unit.

550ZH±01
I32392
3
4
I32393
5
6
I12755
9
12
Ohmmeter
± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
55±19
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT HEATER ASSY
(a) Inspect the water temperature sensor.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals 3 and 4 of heater wire.
Resistance: Refer to the graph
If the resistance is not as specified, replace the heater wire.
(b) Inspect the overheat sensor.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals 5 and 6 of heater wire.
Resistance: Refer to the graph
If the resistance is not as specified, replace the heater wire.
(c) Inspect the glow plug.
(1) Using an ohmmeter, check the continuity by mea-
sure the resistance between terminals 9 and 12 of
heater wire.
Standard resistance: about 0.5
(20
C, reference
value)
If the resistance is over 1
, replace the heater wire.

I32394
1
2
I32395
Wire harness side: 55±20
± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(d) Inspect the flame sensor.
(1) Using an ohmmeter, measure the resistance be-
tween terminals 1 and 2 of heater wire.
Resistance: Refer to the graph
If the resistance is not as specified, replace the heater wire.
2. INSPECT HETER SWITCH ASSY
(a) Disconnect the connector from the power heater switch
and inspect the connector on the wire harness side, as
shown in the chart.
Tester connectionConditionSpecified condition
2 ± GroundConstantContinuity
4 ± GroundConstantContinuity
3 ± GroundTurn ignition switch ONBattery voltage
3 ± GroundTurn ignition switch OFFNo voltage
1 ± GroundTurn light control switch TAIL or HEADBattery voltage
1 ± GroundTurn light control switch OFFNo voltage

If the circuit is as specified, replace the power heat-
er switch.

If the circuit is not as specified, inspect the circuits
connected to other parts.

I32396
From back side:
± HEATER & AIR CONDITIONERCOMBUSTION TYPE POWER HEATER SYSTEM
55±21
AVENSIS REPAIR MANUAL (RM1018E)
(b) Connect the connector to the power heater switch and in-
spect the connector from the back side, as shown in the
chart.
Tester connectionConditionSpecified condition
6 ± GroundTurn the ignition switch ON and power heater
switch ONBattery voltage
6 ± GroundTurn the ignition switch ON and power heater
switch OFFNo voltage

If the circuit is not as specified, replace the power
heater switch.

550ZE±01
±
HEATER & AIR CONDITIONER ELECTRICAL TYPE POWER HEATER SYSTEM
55±13
AVENSIS REPAIR MANUAL (RM1018E)
ELECTRICAL TYPE POWER HEATER SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
PTC heater does not operate, when perform in these conditions:

Engine coolant temp.: 70 C (158 F) or below

Engine speed: 650 rpm or above

Temperature control selector: MAX. HOT

Ambient temperature: Below 10 C (50 F)
1. HTR1 Fuse
2. HTR2 Fuse
3. HTR1 relay
4. HTR2 relay
5. PTC heater
6. ECM
7. Wire harness±
±
±
±
55±14
±
±