2002 TOYOTA AVENSIS check engine

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
±
±

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)

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.

I22118
Condition: Air conditioning system does not function effectively.
I22119
Condition: Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±27
AVENSIS REPAIR MANUAL (RM1018E)
(3) When cooling is insufficient:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is low on both low and
high pressure sides

RHD AZ engine series:
Bubbles are seen through sight
glass continuously

Cooling performance is insuffi-
cient
Gas leakage in refrigeration sys-
tem
Insufficient refrigerant

Refrigerant leakage
(1) Check for gas leakage and re-
pair if necessary
(2) Supply proper amount of new
refrigerant
(3) If indicated pressure value is
close to 0 when connected to the
gauge, vacuum after inspecting
and repairing the location of leak-
age.
(4) When the circulation of the refrigerant is poor:
SymptomProbable causeDiagnosisCorrective Action

Pressure is low on both low and
high pressure sides

Frost exists on piping from con-
denser to A/C unit
Refrigerant flow is obstructed by
dirt in condenserCondenser is cloggedReplace condenser

I22120
Condition: Air conditioning system does not function. (Sometimes it may function)
I22121
Condition : Air conditioning system does not function effectively. 55±28
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(5) When the refrigerant does not circulate:
SymptomProbable causeDiagnosisCorrective Actions

Vacuum is indicated on low pres-
sure side, and extreamly low pres-
sure is indicated on high pressure
side

Frost or dew is seen on piping on
both sides of condenser or expan-
sion valve

Refrigerant flow is obstructed by
moisture or dirt in refrigeration sys-
tem

Refrigerant flow is obstructed by
gas leak from expansion valve
Refrigerant does not circulate
(1) Check the expansion valve
(2) Clean out dirt on expansion
valve by blowing air
(3) Replace condenser
(4) Vacuum and supply proper
amount of new refrigerant
(5) For gas leakage from expan-
sion valve, replace expansion
valve
(6) When the refrigerant is overcharged or cooling of
condenser is insufficient:
SymptomProbable causeDiagnosisRemedy

Pressure is extreamly high on
both low and high pressure sides

RHD AZ engine series:
No air bubbles are seen through
sight glass even when engine rpm
lowers

Excessive refrigerant

Cooling performance of con-
denser is insufficient
Excessive refrigerant

Cooling performance of con-
denser is insufficient
(1) Clean condenser
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, check the amount of refrig-
erant and supply proper amount of
refrigerant

I22122
Condition: Air conditioning system does not function.
NOTE : These gauge indica-
tions occur when the refrigera-
tion system opens and the re-
frigerant is charged without
vacuuming.
I22123
Condition
: Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±29
AVENSIS REPAIR MANUAL (RM1018E)
(7) When there is air in the refrigeration system:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and the high pressure
sides

The low pressure piping is too
hot to touch

RHD AZ engine series:
Bubbles can be seen through sight
glass
Air in refrigeration system

There is air in refrigeration sys-
tem

Vacuuming is insufficient
(1) Check it compressor oil is dirty
or insufficient
(2) Vacuum and supply new refrig-
erant
(8) When the expansion valve malfunctions:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and high pressure sides

Frost or dew is on piping on low
pressure side
Trouble with expansion valve

Excessive refrigerant in low
pressure piping

Expansion valve opened too
wide
Replace expansion valve

± 50 g (± 1.76 oz.)
I37057
0.1 (1.0)0.4 (4.0)
0.3 (3.0)
0.2 (2.0)MPa (kgf/cm
2) Pressure on low pressure side
Outside temperature 0
C (F) 15 (59) 20 (68) 30 (86)25 (77) 35 (95)
0 g (0 oz.)
(Standard)
+ 50 g (+ 1.76 oz.)
± HEATER & AIR CONDITIONERREFRIGERANT
55±31
AVENSIS REPAIR MANUAL (RM1018E)
3. w/ Hot gas heater:
INSPECT REFRIGERANT VOLUME
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the the manifold gauge pres-
sure when these conditions are established.
Test conditions:

Engine is at idle.

Blower speed control switch is at ºHIº.

Temperature control dial is at ºMAX. COOLº.

Engine has been warmed up.

All doors are fully open.

Hood is fully open.

Air inlet mode selector damper is at RECIRE.

Air outlet damper is at FACE.

Outside temperature is 15 ± 35
C (59± 95

F).
(b) Check refrigerant volume according to the graph below.
RangeAmount of refrigerantCorrective actions
Except range belowInsufficient or excessive
Supply refrigerant until low
pressure become within
the standard
50 g
(
1.76 oz.), or remove
refrigerant and then sup-
ply proper amount of re-
frigerant
Standard
50 g
(
1.76 oz.)Proper±

550Z8±01


I37091
Over charged Mean
value
in proper
range
Hight
Pressure
Refrigerant Amount
30 g (
1.06 oz.) Amount to be charged
Sub±cool system RHD AZ Engine series: 55±38
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Turn the A/C switch ON.
(b) Operate the cooler compressor at the engine rpm of approx. 1,000 for 5 to 6 minuites to circulate the
refrigerant and collect the compressor oil remaining in each component into the cooler compressor as
much as possible.
(c) Shut off the engine.
(d) Let the refrigerant gas out.
SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070,
07117±88080)
2. CHARGE REFRIGERANT
(a) Using a vacuum pump, perform vacuuming.
(b) Charge refrigerant, HFC±134a (R134a).
Standard: 440
30 g (15.51
1.06 oz.)
SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050,
07117±88060, 07117±88070, 07117±88080)
3. WARM UP ENGINE
4. INSPECT LEAKAGE OF REFRIGERANT
(a) Using a gas leak detector, check for leakage of the refrigerant.
NOTICE:
1CD±FTV Hot gas heater:
Since the system uses a refrigerant filter (fixed valve), sound of the refrigerant circulation (hissing
sound) can be heard for approx. 30 seconds after turning the A/C off. This is merely a sound of bal-
ancing the low pressure with the high pressure, not a sound of abnormality.