2005 TOYOTA AVENSIS diagnostic

I35431
Buner 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
2BR
G
L±Y
L B±R
Y
L±WR
1
2
3
4 5
6
7
8W±B Connector A
IG
R±G
R±L (*1)
R±Y (*2)
R±B
W±R (*1)
Y±R (*2)
*1: TMC Made
*2: TMUK Made
± DIAGNOSTICSCOMBUSTION TYPE POWER HEATER SYSTEM
05±1165
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 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
(a) The ECU is able to store upto 5 pieces of faulty memory. If it is full, the new data is written over F5.
4. WIRING DIAGRAM

05C7U±01
I35990
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)
DTC Check1st Time
2nd Time
Normal Code
Malfunction Code (Code )

Normal Code
Malfunction Code (Code )
AIR CONDITIONING SYSTEM Check Sheet
± DIAGNOSTICSCOMBUSTION TYPE POWER HEATER SYSTEM
05±1163
AVENSIS REPAIR MANUAL (RM1018E)
CUSTOMER PROBLEM ANALYSIS CHECK

05C7T±01
±
DIAGNOSTIC SCOMBUSTION TYPE POWER HE ATER SYSTEM
05± 1161
A VENSIS RE PAIR MANUAL (RM1018E)
COMBUSTIO N TYPE POWER HE ATER SYSTEM
HOW T O PROCEED WITH TROUBLESHOOTING
1 VEHICL E BROUGHT TO WORK SHOP
2 CUSTOMER PROBLEM ANA LYSIS ( See page 05± 1163 )
3 CHECK AND CLEAR DTC ( See page 05±1164 )
4 PROBLEM SYMPTOM CONFIRMATION
SYMPTOM OCCUR (GO TO STEP 6)
SYMPTOM DOES NOT OCCUR (GO TO
STEP 5)
5 SYMP TOM SIMUL ATION ( See page 01±22 )
6 DTC CHECK ( See page 05±1164 )
7 DTC CHART ( See page 05±1166 )
8 PROBLEM SYMP TOMS TABLE ( See page 05± 1170 )
9 CIRCUIT INSPECTION ( See page 05±1171 to 05± 1179 )
10 IDENTIFICATION OF PROBLEM

05±1162
± DIAGNOSTICSCOMBUSTION TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
11 PARTS INSPECTION
12 REPAIR
13 CONFIRMATION TEST
14 END

I35396
R±W (*2) R±W (*2, *1) G±Y (*1)
W±B (*1)
W±B
(*1) R±W (*3, *1)
R±W (*3)
R±W (*2)CB1
CK 12 Center J/BP5
Power Heater SWA/C Control Assembly
A1611
J/C
J26H
J27F3IG
IN 6
E2
A
A J16
J/C
Driver Side J/B
DC6
From
HTR Fuse
ILHOTGASIN
*1: 1CD±FTV
*2: LHD
*3: RHD
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1159
AVENSIS REPAIR MANUAL (RM1018E)
HOT GAS HEATER SWITCH CIRCUIT
CIRCUIT DESCRIPTION
Hot gas heater performs only when its switch turns to ON and fulfill the following 6 conditions.

Hot gas heater switch is ON.

Recirculation damper position is FRS.

Blower motor switch is in the position other than OFF.

Ambient temperature varies according to the following condition;
A/C switch ONBelow ±1.5C (32F)
A/C switch OFFBelow 8C (46F)

Air mix damper position is MAX HOT.

Water temperature is 70C (158F) or less.
WIRING DIAGRAM
05C7S±01

I32396IG
IN
E
ILL+
ILL±
I36144
HOTGASIN
A16A15
I32395
E
05±1160
±
DIAGNOSTICS AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
1INSPECT HETER SWITCH ASSY
(a)Check that the continuity when connecting the positive tester lead (+) and the negative tester lead (±) to the fol-
lowing terminals.
Standard:
Heater switch conditionConnecting terminalsStandard value
ONIG ± INContinuity
OFFIG ± INNo continuity
ONIG ± EContinuity
OFFIG ± ENo continuity
ONILL+ ± ILL±Continuity
OFFILL+ ± ILL±Continuity
NGREPAIR OR REPLACE HETER SWITCH ASSY
OK
2CHECK WIRE HARNESS(A/C CONTROL ASSEMBLY ± BATTERY)
(a)Remove the A/C amplifier with connectors being con- nected.
(b)Turn the ignition switch to ON.
(c)Measure the voltage between terminal HOTGASIN and GND of the A/C amplifier.
Standard:
Heater switch conditionStandard value
ON10 to 14 V
OFF0 V
NGREPAIR OR REPLACE WIRE HARNESS
OK
3CHECK WIRE HARNESS(HETER SWITCH ± BODY GROUND)
(a)Check for an open or short circuit in harness and connec- tor between heater switch and body ground
(See page 01±32).
NG REPAIR OR REPLACE WIRE HARNESS
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE

I35380
R±W
(*2)J26 J26HH
IE111
IE218
A157
MGV A/C Control Assembly
R±W
(*2)R±W R±B R±Y J/CC4
Condenser
Assembly
12
Driver Side J/B
DC6
DB5
R±W
(*1)
From
HTR Fuse
*1: LHD
*2: RHD
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1157
AVENSIS REPAIR MANUAL (RM1018E)
HOT GAS HEATER MAGNETIC VALVE CIRCUIT
CIRCUIT DESCRIPTION
For the hot gas heater, it is necessary to fulfill the following 6 conditions.

Hot gas heater switch is ON.

Recirculation damper position is FRS.

Blower motor switch is in the position other than OFF.

Ambient temperature varies according to the following condition;
A/C switch ONBelow ±1.5C (32F)
A/C switch OFFBelow 8C (46F)

Air mix damper position is MAX HOT.

Water temperature is 70C (158F) or less.
WIRING DIAGRAM
05C7R±01

I36144
MGV
A16A15
I36136
05±1158
±
DIAGNOSTICS AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
1INSPECT AIR CONDITIONING AMPLIFIER
(a)Remove the A/C amplifier with connectors being con- nected.
(b)Measure the voltage between terminals MGV of the A/C amplifier and body ground.
Standard:
Recirculation switchVoltage (V)
OperateBelow 1.0
Not OperateNo Continuity
OKPROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
NG
2INSPECT W/RECEIVER CONDENSER ASSY
(a)Apply voltage between terminals and check that the re- frigerant passages switch.
NGREPLACE W/RECEIVER CONDENSER ASSY
OK
3CHECK WIRE HARNESS(W/RECEIVER CONDENSER ASSY ± AIR CONDITIONING AMPLIFIER)
(a)Check for an open or short circuit in harness and connector between w/ receive\
r condenser assy and
A/C amplifier (See page 01±32).
NG REPAIR OR REPLACE WIRE HARNESS
OK
REPLACE AIR CONDITIONING AMPLIFIER