2005 TOYOTA AVENSIS Break

± 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.

±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±15
AVENSIS REPAIR MANUAL (RM1018E)
18. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT
DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the center pillar of the vehicle or its periphery is damaged, check if \
there is any damage to the
side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with
a new one:
If there are any defects as mentioned below, replace the side airbag sensor with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
19. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the front seat airbag assy and side airbag sensor assy (See page 60±66).
20. AIRBAG SENSOR REAR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
21. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the quarter panel of the vehicle or its periphery is damaged, check if \
there is any damage to the airbag sensor rear. If there are any defects as mentioned below, replace the airbag sensor rear with
a new one:
If there are any defects as mentioned below, replace the airbag sensor rear with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
22. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the curtain shield airbag assy and airbag sensor rear (See page 60±68).
23. SEAT POSITION AIRBAG SENSOR (VEHICLES NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
24. SEAT POSITION AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check for damage to the seat position airbag sensor even if th\
e airbag was not deployed:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.
25. WIRE HARNESS AND CONNECTOR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
26. WIRE HARNESS AND CONNECTOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Check for breaks in all wires of the SRS wire harness, and exposed condu\
ctors.
(c) Check to see if the SRS wire harness connectors are cracked or chipped.
HINT:
The SRS wire harness is integrated with the engine room main wire, instrume\
nt panel wire floor wire, floor
wire No.2 harness assembly.

H40181
Claw
Groove
H42905
Fig.1
Fig.2
Power Source
Safing
Sensor
Squibs
Deceleration
Sensor 60±6
± SUPPLEMENTAL RESTRAINT SYSTEMSUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(5) Connector lock mechanism:
Locking the connector lock button connects the
connector securely.
(b) When the vehicle is involved in a frontal collision in the
hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. The
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensor. As illustrated in the Fig.
2, ignition is caused when current flows to the squib,
which happens when the safing sensor and the decelera-
tion sensor go on simultaneously. When a deceleration
force acts on the sensors, 3 squibs in the driver airbag,
front passenger airbag and knee airbag ignite and gener-
ate gas. The gas discharging into the driver airbag, front
passenger airbag and knee airbag rapidly increases the
pressure inside the bags, breaking the horn button assy
and instrument panel. The inflation of the bag then ends,
and the bags deflate as the gas is discharged through dis-
charge holes at the bag's rear or side.

670SA±01

I35188

I35189
(2)
(1)
(3)
H02440
Riveter
Mandrel
±
AUDIO & VISUAL SYSTEM REAR SPEAKER ASSY
67±13
AVENSIS REPAIR MANUAL (RM1018E)
REAR SPEAKER ASSY
REPLACEMENT
1.REMOVE REAR DOOR WINDOW REGULATOR HANDLE ASSY (See page 75±22)
2.REMOVE REAR DOOR TRIM BASE LH (See page 75±22)
3. REMOVE POWER WINDOW REGULATOR SWITCH ASSY REAR (W/ POWER WINDOW)
(See page 75±22)
4.REMOVE REAR DOOR TRIM BOARD SUB±ASSY LH (See page 75±22)
5. REMOVE REAR SPEAKER ASSY
(a) Disconnect the connector.
(b) Using a drill of less then
4 mm (0.16 in.), drill out the 3
rivet heads and remove the rear speaker assy from the
rear door panel.
(c) Gently and vertically put the drill to the rivet, and cut the
rivet flanges.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Take care as the cut rivet is hot.
(d) Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
(e) Using a vacuum cleaner, remove the drilled rivets and their dust from the inside of the rear door panel.
6. INSTALL REAR SPEAKER ASSY
(a) Using an air riveter or a hand riveter, install 3 new strike rivets to install the rear speaker assy on the rear door pan-
el.
NOTICE:

Install the new strike rivet in order shown in the il-
lustration to install the rear speaker assy.

Do not prize a riveter, as the riveter could be dam-
aged, loosened and the mandrel could be bent.

670S8±01

I35168

I35169
(2)
(1)
(3)
H02440
Riveter
Mandrel
67±10
±
AUDIO & VISUAL SYSTEM FRONT NO.1 SPEAKER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
FRONT NO.1 SPEAKER ASSY
REPLACEMENT
1. REMOVE REAR DOOR WINDOW REGULATOR HANDLE ASSY (W/O POWER WINDOW) (See page 75±8)
2.REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page 75±8)
3.REMOVE FRONT DOOR TRIM BASE LH (See page 75±8)
4.REMOVE FUEL LID OPENER SWITCH (See page 75±8)
5. REMOVE POWER WINDOW REGULATOR SWITCH ASSY (W/ POWER WINDOW) (See page 75±8)
6.REMOVE FRONT DOOR TRIM BOARD SUB±ASSY LH (See page 75±8)
7. REMOVE FRONT NO.1 SPEAKER ASSY
(a) Disconnect the connector.
(b) Using a drill of less then
4 mm (0.16 in.), drill out the 3
rivet heads and remove the front No.1 speaker assy from
the front door panel.
(c) Gently and vertically put the drill to the rivet, and cut the rivet flanges.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Take care as the cut rivet is hot.
(d) Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
(e) Using a vacuum cleaner, remove the drilled rivet and their
dust from the inside of the front door panel.
8. INSTALL FRONT NO.1 SPEAKER ASSY
(a) Using an air riveter or a hand riveter, install 3 new strike rivets to install the front No.1 speaker assy on the front
door panel.
NOTICE:

Install the new strike rivet in order shown in the il-
lustration to install the front No.1 speaker assy.

Do not prize a riveter, as the riveter could be dam-
aged, loosened and the mandrel could be bent.

660CQ±01
E60751
60

E60704
Push
Pull
Stopper
E59361
Curve 66±20
± WIPER & WASHERREAR WIPER RUBBER
AVENSIS REPAIR MANUAL (RM1018E)
REAR WIPER RUBBER
REPLACEMENT
1. REMOVE REAR WIPER BLADE ASSY
(a) Remove the rear wiper arm head cap.
(b) Raise the rear wiper blade to the position as shown in the
illustration where the meshing of the claw is disengaged
with the click sound.
NOTICE:
Be careful not to break the claw.
(c) Pull the rear wiper blade straight from the wiper arm to-
ward the left side of the vehicle.
NOTICE:
Do not fold the rear wiper arm with the rear wiper blade be-
ing removed from it.
2. REMOVE REAR WIPER RUBBER
(a) Pull the end of the rubber protruded from the blade stop-
per as shown in the illustration.
NOTICE:
Do not pull out the wiper rubber forcibly. Otherwise, the
backing plates are deformed or blade claw is damaged.
HINT:
Pushing the position close to the middle of the blade raises the
rubber, making easier to pull the rubber out.
3. INSTALL REAR WIPER RUBBER
(a) Install the 2 wiper rubber backing plates to the rear wiper
rubber.
NOTICE:
Be sure to install the wiper rubber backing plates in the
right direction.

B69067
Butyl Tape
B66981
B68929
B61431
75±10
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE FRONT DOOR SERVICE HOLE COVER
(a)Remove the service hole cover.
NOTICE:
Remove the tape remaining on the door side.
(b)Remove the lower frame seal.
9.REMOVE OUTER REAR VIEW MIRROR ASSY LH
(a)Disconnect the mirror connector.
(b)Remove the 3 screws and mirror.
NOTICE:
When the screws are removed, the mirror may fall and be-
come deformed.
10.REMOVE FRONT NO.1 SPEAKER ASSY (W/ SPEAKER)
(a)Using a drill of less than ù 4 mm (0.16 in.), drill out the 3 rivets heads and remove the speaker.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Be careful with the cut rivet, because it is hot.
(b)Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
(c)Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.
11.REMOVE FRONT DOOR BELT MOULDING ASSY LH (See page 76±23)
12. REMOVE FRONT DOOR STIFFENER CUSHION NO.1
(a) Using a screwdriver, disengage the 2 claws and remove the cushion.
13. REMOVE FRONT DOOR SPACER LH
(a) Using a screwdriver, disengage the 2 claws and remove the spacer.