2002 TOYOTA AVENSIS Repair Manual

550ZF±01
I32391
55±14
± HEATER & AIR CONDITIONERELECTRICAL TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT HEATER ASSY
(a) Check continuity.
(1) Using an ohmmeter, check for continuity between
each terminal of connector and earth wire.
If no continuity, replace the heater radiator.

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
±
±

550ZF±01
I32391
55±14
± HEATER & AIR CONDITIONERELECTRICAL TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT HEATER ASSY
(a) Check continuity.
(1) Using an ohmmeter, check for continuity between
each terminal of connector and earth wire.
If no continuity, replace the heater radiator.

550YS±01
I35345Claw
I35346
I35347
I35348
55±100
±
HEATER & AIR CONDITIONER HEATER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
HEATER ASSY
REPLACEMENT
1.REMOVE AIR CLEANER ASSY (See page 11±82)
2.REMOVE FUEL FILTER ASSY (See page 11±82) 3. REMOVE AIR DUCT NO.3
(a) Release the claw fitting and remove the bolt and the en-gine room relay No.2 block.
(b) Remove the clip and the air duct No.3.
4. DISCONNECT HEATER INLET WATER HOSE
(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose.
HINT:
Prepare a support plate and waste to catch the leaked coolant.
5. DISCONNECT HEATER WATER INLET HOSE A
(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose A.
HINT:
Prepare a support plate and waste to catch the leaked coolant.

I35349
I35350
I35350
I35349
±
HEATER & AIR CONDITIONER HEATER ASSY
55±101
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE HEATER ASSY
(a) Using pliers, grip the claws of the clip and slide the clip to
disconnect the heater fuel hose.
HINT:
Prepare a support plate and waste to catch the leaked fuel.
(b) Disconnect the connector.
(c) Remove the 2 bolts and the heater assy.
7. INSTALL HEATER ASSY
(a) Install the heater assy with the 2 bolts. Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
(b) Connect the connector.
(c) Install the heater fuel hose.
HINT:
Prepare a support plate and waste to catch the leaked fuel.
8.INSTALL FUEL FILTER ASSY (See page 11±82)
9.INSTALL AIR CLEANER ASSY (See page 11±82)
10.ADD ENGINE COOLANT (See page 16±44)
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±37)
12.CHECK FUEL LEAK (See page 11±56)

550ZI±01
I35437
Connector ºBº Wire harness side:
Connector ºAº
I36091
Connector ºBº From back side:
Connector ºAº 55±22
± HEATER & AIR CONDITIONERHOT GAS TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
HOT GAS TYPE POWER HEATER SYSTEM
ON±VEHICLE INSPECTION
1. INSPECT AIR CONDITIONING CONTROL ASSY
(a) Disconnect the connector from air conditioning control assy and inspect the connector on wire harness
side, as shown in the table.
Symbols (Terminal No.)Wiring ColorConditionSTD Voltage (V)
SOL+ (B17) ±
GND (B40)R ± W±BStart engine
Compressor: OperatePulse generation
MGV (B14) ±
GND (B40) (*1)R±Y ± W±BStart engine
Compressor: OperatePulse generation
HOT GAS IN (B22) ±
GND (B40) (*1)R±Y ± W±BIG SW: ON
Hot Gas SW: ONBattery positive voltage
If circuit is not as specified, try replacing the air conditioning control assy with a new one. If the circuit is not
as specified, inspect the circuits connected to the other parts.
(b) Connect the connector to air conditioning control assy and inspect wire harness side connector from
the back side, as shown in the table.
Symbols (Terminal No.)ConditionSpecified condition
HI (A4) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
HINo continuity
Continuity
M2 (A5) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
M2No continuity
Continuity
M1 (A6) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
M1No continuity
Continuity
GND (A1) ± Body groundIgnition switch ON
Turn blower dial: OFF
LONo continuity
Continuity

550ZJ±01
I36136
I32396
E
IN
IG
± HEATER & AIR CONDITIONERHOT GAS TYPE POWER HEATER SYSTEM
55±23
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT W/RECEIVER CONDENSER ASSY
(a) Apply voltage between terminals and check that the re-
frigerant passages switch.
2. INSPECT HETER SWITCH ASSY
(a) Check that the continuity to the follwing terminals.
Standard:
Heater switch conditionConnecting terminalsStandard value
ONIG ± INContinuity
OFFIG ± INNo continuity
ONIG ± EContinuity
OFFIG ± ENo continuity

550Z7±01
I35292
Sight Glass
55±24
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
REFRIGERANT
ON±VEHICLE INSPECTION
1. RHD AZ Engine series:
INSPECT REFRIGERANT VOLUME
(a) Observe the sight glass on the cooler refrigerant liquid
pipe A.
Test conditions:

All doors are fully open.

Temperature control dial is at ºMAX. COOLº.

Engine is running at 1,500 rpm.

Blower speed control switch is at ºHIº.

A/C switch is ON.
ItemSymptomAmount of refrigerantCorrective Actions
1Bubbles existInsufficient*
(1) Check for gas leakage and repair if nec-
essary
(2) Add refrigerant until bubbles disappear
2No bubbles existEmpty, insufficient or excessiveRefer to 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage and repair if nec-
essary
(2) Add refrigerant until bubbles disappear
4Considerable temperature difference be-
tween compressor inlet and outletProper or excessiveRefer to 5 and 6
5Immediately after air conditioning is turned
off, refrigerant remains clearExcessive
(1) Discharge refrigerant
(2) Vacuum and supply proper amount of
new refrigerant
6
Immediately after air conditioning is turned
off, refrigerant foams and then becomes
clear
Proper±
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.