2005 TOYOTA AVENSIS fuel pressure

05CP9±01
A81021
Common Rail System Diagram (1CD±FTV Fuel System)
Sensors
ECM
EDU
Common Rail
Fuel Pressure SensorPressure Discharge
Valve
Supply Pump Assy
Suction Control ValveFuel TankInjector
Fuel Filter
: High±pressure Area
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±517
AVENSIS REPAIR MANUAL (RM1018E)
ECD SYSTEM (1CD±FTV)
DESCRIPTION
1. COMMON RAIL SYSTEM
The common rail system stores high±pressure fuel supplied from the supply pump in the common rail and
injects it using the injector. Fuel injection timing and fuel injection volume are regulated by the ECM; it pro-
vides an electric current to the solenoid valve of the injector with the EDU to regulate them.
By storing high±pressure fuel produced in the supply pump in the common rail, this system can always offer
stable fuel injection pressure regardless of the engine speed and engine load, even if a driving speed is low.
In addition, this system uses the injector that opens and closes its fuel passage with the Two±Way±Valve
(TWV) therefore both the fuel injection time and volume are precisely regulated by the ECM.
The ECM monitors internal fuel pressure of the common rail with the fuel pressure sensor and commands
the supply pump to supply fuel to obtain a target internal pressure (approximately 30 to 180 MPa (306 to
1,835 kgf/cm
2, 4,351 to 26,106 psi)). The ECM opens and closed the pressure discharge valve to improve
controllability for the common rail internal fuel pressure.
This system has two divisional fuel injections. It performs ºpilot±injectionº as subsidiary fuel injection prior
to the main fuel injection to make combustion soft, and this helps to reduce engine vibration and noise.

A81477
Engine Control System Diagram
Accelerator Pedal
Position Sensor
Ignition
Switch Signal
Starter Signal
Vehicle Speed Signal
DLC3
Battery Voltage
Other Signal
Fuel Tank
Suction Control Valve
Supply Pump
Generator
ECMPressure Discharge Valve
Fuel Pressure Sensor
EDU Relay
EDU
Mass Air Flow Meter
Atmospheric
Temp. SensorEGR Cooler
Turbo ChargerInter Cooler
Intake Shatter
Intake Air Temp.
SensorEGR Valve
Injector
Manifold
Absolute
Sensor
Glow
Plug
Glow
Relay Crankshaft Position Sensor VRV for
Turbo
ChargerEngine Coolant
Temp. SensorCamshaft
Position
SensorCommon Rail
Vacuum Pump
(INJT PRD)(INJF)
05±518
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
COMMON RAIL SYSTEM COMPONENTS:
ComponentDescription
Common railStore high±pressure fuel produced by the supply pump
Supply pumpOperated by the crankshaft, and supply high±pressure fuel to the common rail
InjectorInject fuel to the combustion room based on signals from the ECM
Fuel pressure sensorMonitor internal fuel pressure of the common rail and send signals to the ECM
Pressure discharge valveBased on signals from the ECM, open the valve when sudden deceleration is occurred, or when the ignition switch is
OFF to prevent the fuel pressure from being too high
Suction control valveBased on signals from the ECM, adjust fuel volume supplied to the common rail and regulate the internal fuel pres-
sure
2. ENGINE CONTROL SYSTEM

A81479
Injection Control Diagram
Accelerator Pedal
Position Sensor
Camshaft Position Sensor
Crankshaft Position Sensor
(NE Signal)
Other Sensor
Fuel TankFeed
Pump
Eccentric
CamPlungerCheck Valve Fuel Pressure SensorCommon Rail EDU
TWV
Orifice
Orifice
Nozzle
NeedleControl
Chamber
Piston
Injector ECM
Suction
Control
Valve
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±519
AVENSIS REPAIR MANUAL (RM1018E)
3. INJECTION CONTROL SYSTEM
The ECM controls the fuel injection system using the injector and the supply pump. The ECM determines
the fuel injection volume and injection timing by controlling duration and timing of the energizing to the sole-
noid valve of the injector, and determines injection pressure by controlling the Suction Control Valve located
on the supply pump.
The feed pump is used to pump fuel from the fuel tank into the supply pump.

A81483
Suction Control Valve
Opening Small
Operation DiagramPlunger
Top±Dead CenterPlunger
Bottom±Dead CenterPumping
Starting Point
Cam
Stroke: Fuel Pumping Volume
Check Valve
Small
Suction
Area(1)
(2)(3)
(1) (2) (3) Suction
Control
Valve
A81484
Pumping
Starting Point
Large
Suction
Area
(1)
(2)(3) Cam
Stroke
(1) (2) (3): Fuel Pumping Volume Suction Control Valve
Opening Large
Operation Diagram
Suction
Control
Valve
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±521
AVENSIS REPAIR MANUAL (RM1018E)
5. SUCTION CONTROL VALVE OPERATION SYSTEM
HINT:
The ECM controls the suction control valve operation to regulate the fuel volume that is pumped by the sup-
ply pump to the common rail. Consequently, the fuel pressure in the common rail is controlled to the target
injection pressure.
(a) Suction control valve opening small:
(1) When the opening of the suction control valve is small, the fuel suction area is kept small, there-
fore the transferble fuel volume is decreased.
(2) The suction volume becomes small due to the small suction area, despite the plunger stroke is
full. Therefore, the difference of the volume between the geometry volume and the suction vol-
ume is in vacuum condition.
(3) Pumping will start at the time when the fuel pressure has become higher than the common rail
pressure.
(b) Suction control valve opening large:
(1) When the opening of the suction control valve is large, the fuel suction area is kept large, there-
fore the transferble fuel volume is increased.
(2) If the plunger strokes fully, the suction volume will increase because the suction area is large.
(3) Pumping will start at the time when the fuel pressure has become higher than the common rail
pressure.

P0087 (See page 05±557)
P0088 (See page 05±563)
P0093 (See page 05±570)
P0190 (See page 05±557)
P0192 (See page 05±557)
P0193 (See page 05±557)
P0200 (See page 05±604)
P0627 (See page 05±655) P1229 (See page 05±563)
P1271 (See page 05±663) P1272 (See page 05±663) P1238 (See page 05±658) DTC No. A
BCDE F
GH IJKL
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P0191 (See page 05±603)


( ): Potential DTC codes
(
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05±522
±
DIAGNOSTICS ECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
6. DIAGNOSTICS TROUBLE CODE MATRIX FOR FUEL SYSTEM
HINT:
This matrix indicates typical DTC codes combinations for each malfunctio\
n occurrence.
Trouble areaMalfunctionRefer to
Open or short in injector circuitA
InjectorStuck openBj
Stuck closeC
Fuel pressure sensorOpen or short in fuel pressure sensor circuit or
pressure sensor output fixedD
Open or short in pressure discharge valve circuitE
Pressure discharge valveStuck openFg
Stuck closeG
Open or short in suction control valve circuitH
Suction control valveStuck openI
Stuck closeJ
EDUFaulty EDUK
Common rail system (Fuel system)Fuel leaks in high±pressure areaL
7. DIAGNOSTICS TROUBLE CODE DESCRIPTION
DTC No.Description
P0087Fuel pressure sensor output status at fixed value
P0088Internal fuel pressure too high (200 MPa (2,039 kgf/cm2, 29,007 psi) or more)
P0093Fuel leaks in high±pressure area
P0190Open or short in fuel pressure sensor circuit (Low or high output)
P0191Fuel pressure sensor out of range (Low output)
P0192Open or short in fuel pressure sensor circuit (High output)
P0193Open or short in fuel pressure sensor circuit (Sensor 1 and/or 2 relati\
on)
P0200Open or short in EDU or injector circuit
P0627Open or short in suction control valve circuit
P1229Fuel over fed
P1238Injection malfunction, exclude open or short in injector circuit
P1271Open or short in pressure discharge valve circuit
P1272Closed malfunction of the pressure discharge valve

A06532
1,900 4.5
1
13.3
100
kPa
mmHg
Air Pressure V
253.3
(3.9) (74.8) (in.Hg) 05±584
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0105 MANIFOLD ABSOLUTE
PRESSURE/BAROMETRIC PRESSURE
CIRCUIT
DTC P0107 MANIFOLD ABSOLUTE
PRESSURE/BAROMETRIC PRESSURE
CIRCUIT LOW INPUT
DTC P0108 MANIFOLD ABSOLUTE
PRESSURE/BAROMETRIC PRESSURE
CIRCUIT HIGH INPUT
CIRCUIT DESCRIPTION
By a built±in sensor unit, the manifold absolute pressure sensor
detects the intake manifold pressure as a voltage. The ECM
then determines the basic injection duration and basic ignition
advance angle based on this voltage.
Since the manifold absolute pressure sensor does not use the
atmospheric pressure as a criterion, but senses the absolute
pressure inside the intake manifold (the pressure in proportion
to the preset absolute vacuum 0), it is not influenced by fluctua-
tions in the atmospheric pressure due to high altitude and other
factors. This permits it to control the air fuel ratio at the proper
level under all conditions.
DTC No.DTC Detection ConditionTrouble Area
P0105
P0107
P0108Open or short in manifold absolute pressure sensor circuit for
0.5 sec. or more (1 trip detection logic)

Open or short in manifold absolute pressure sensor circuit

Manifold absolute pressure sensor

Turbocharger assy

EGR valve assy

ECM
HINT:
After confirming DTC ºP0105, P0107 or P0108º, use the hand±held tester to confirm the intake air tempera-
ture from the ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / PIMº.
Intake Manifold Pressure (kPa)Malfunction
Approx. 0
PIM circuit short
250 or more

VC circuit open or short

PIM circuit open

E2 circuit open
05CPJ±01

05±570
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0093FUEL SYSTEM LEAK DETECTED ± LARGE LEAK
HINT:

For more information on the common rail system, see page 05±517.

If P0093 is present, use the diagnostic trouble code matrix for fuel sys\
tem, see page 05±517.
CIRCUIT DESCRIPTION
Refer to description on page 05±517.
DTC No.DTC Detection ConditionTrouble Area
P0093Fuel leaks in high±pressure area.

Fuel line between supply pump and common rail

Fuel line between common rail and injector

Supply pump

Common rail

Injector (P1238 is set simultaneously)

Pressure discharge valve

Open or short in EDU circuit (P0200 is set simultaneously 

Open or short in injector circuit (P0200 and P1238 are set
simultaneously)

EDU (P0200 is set simultaneously 

ECM
HINT:
After confirming DTC P0093, use the hand±held tester to confirm the fuel rail pressure fro\
m the ºDIAGNOSIS
/ OBD/MOBD / DATA LIST / ALL / COMN RAIL PRESSº.
Engine SpeedFuel Pressure (MPa)
IdlingApprox. 30 to 40
Running the engine at 2,500 rpm (No engine load)Approx. 50 to 100
MONITOR DESCRIPTION
P0093 (Fuel leaks in high±pressure area):
This DTC stands for fuel leaks is existing in high±pressure area in the c\
ommon rail system. The ECM
constantly monitors the internal fuel pressure of the common rail after the engine is started, and the ECM
then will set this DTC if the decreasing rate of the internal fuel press\
ure is large when injecting the fuel.
In the common rail system, high±pressure fuel (approx. 30 to 180 MPa (\
306 to 1,835 kgf/cm
2, 4.351 to
26,106 psi)) is always applied to the high±pressure area including the su\
pply pump, common rail, injector
and piping. The ECM adjusts the suction control valve opening angle to obtain the target internal fuel pres-
sure.
If this DTC is present, the ECM enters fail±safe mode and permits drivi\
ng the vehicle for extra 1 minute before
stopping both the fuel injection and supply pump operation, then stops the engine\
. The fail±safe mode will
continue until the ignition switch is turned OFF.
MONITOR STRATEGY
Required sensorsFuel pressure sensor
Frequency of operationContinuous
Duration1 sec.
CHK ENG operation1 driving cycle
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
Engine speed600 rpm±
The monitor will not run if the fuel pressure sensor, or suction control valve circuit, or pressure discharge valve is malfu\
nct ioning
05CPF±01

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±571
AVENSIS REPAIR MANUAL (RM1018E)
TYPICAL MALFUNCTION THRESHOLDS
Threshold
Drop rate in the internal fuel pressure is large when injecting fuel
INSPECTION PROCEDURE
HINT:
Read freeze frame data using \b
 . Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determi\
ning whether the vehicle was running
or stopped, the engine was warmed up or not, etc. at the time of the malfu\
nction.
1CHECK OTHER DTC OUTPUT(BESIDES DTC P0093)
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch ON and push the hand±held tester main switch \
ON.
(c)Select the item ºDIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODESº.\
(d)Read the DTCs.
Result:
Display (DTC output besides DTC P0093)Proceed to
Only DTC P0093 is outputA
DTC P1238 is outputB
DTC ºP0200 and/or P1271º are outputC
HINT:
If any other codes besides ºP0093º are output, perform the troublesh\
ooting for those DTCs first.
BGo to step 3
CGO TO RELEVANT DTC CHART (See page 05±544)
A
2CHECK FUEL LEAKAGE(INSPECT HIGH±PRESSURE FUEL PARTS AND AREA FOR FUEL LEAKS)
(a)Visually check the supply pump, injector and fuel line located between the suppl\
y pump and the com-
mon rail for fuel leaks or fuel pressure leaks. Also, perform the same on t\
he fuel line between the com-
mon rail and the injector (See page 11±69, 11±60).
HINT:
Fuel leaks inside the components (Supply pump, etc) may result.
NG REPAIR OR REPLACE
OK