2005 TOYOTA AVENSIS fuel pressure

A81504
Injector Cross Section DiagramPiston
Solenoid Valve
Nozzle Needle
05±658
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP1238INJECTOR MALFUNCTION
HINT:

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

If P1238 is present, use the diagnostic trouble code matrix for fuel sys\
tem, see page 05±517.
CIRCUIT DESCRIPTION
The ECM detects combustion deterioration for specific cylinder.
HINT:

The cylinder that has compensation learned value for INJ VOL varies from other cylinders may be mal-
functioning.

If DTC P0093 (Fuel leaks in high±pressure area) is present simultan\
eously, leakage malfunction of the
cylinder probably be occurred.

If DTC P0200 (Open or short in EDU or injector circuit) is present sim\
ultaneously, there probably be
faulty circuit located between the ECM and the injector including the ED\
U.

If only DTC P1238 (Injector malfunction) is present, probably the injector is \
mechanical malfunction
or insufficient compression (valve clearance, etc) has occurred, not an open o\
r short malfunction of
the ECM, EDU and injector circuit.

Solenoid valve of the injector is the same type of the pressure discharg\
e valve.
05CQ0±01

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±659
AVENSIS REPAIR MANUAL (RM1018E)DTC No.
DTC Detection ConditionMain Trouble AreaRelated Trouble Area
P1238Engine speed variation is large when idling.


Injector

EDU (P0200is set simultaneous-
ly)

Open or short in engine wire
(P0200is set simultaneously)

Connector connection (P0200is
set simultaneously)

Compression pressure

Valve clearance

Valve timing

ECM
HINT:
After confirming DTC P1238, use the hand±held tester to confirm the fuel pressure inside the common rail
in 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
P1238 (Injection malfunction, exclude open or short in injector circuit):
This DTC will be set if the engine speed variations between each cylinder is\
large. The ECM monitors
changes in the crankshaft rotation speed using the crankshaft position sensor f\
or detecting poor combus-
tion. Also, it identifies faulty cylinder using the camshaft position sensor. The fluctuation counter increments
when irregular crankshaft rotation speed variation exceeds the threshold at i\
dling. Therefore, either one of
the cylindershas very poor combustion (Rough idle), the ECM sets this DTC.
MONITOR STRATEGY
Required sensorsCrankshaft position sensor
Frequency of operationContinuous
Duration10 min.
CHK ENG operation2 driving cycles
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
EngineAt idling
Engine speed500 rpm±
Engine coolant temperature20 C (68 F)
TYPICAL MALFUNCTION THRESHOLDS
Threshold
The number of irregular changes in the crankshaft rotation speed
HINT:
The number of irregular changes in the crankshaft rotation speed indicat\
es the insufficient combustion cylin-
der.
WIRING DIAGRAM
Refer to DTC P0200 on page 05±604.

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 7
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Front suspension crossmember sub −assy x Rear engine mounting bracket8788764
Front suspension crossmember sub −assy x Front engine mounting bracket5253038
Front suspension crossmember sub −assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub −assy1331,35698
Front suspension member brace x Body8081659
Return tube sub −assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting blacket5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Air tube No. 2 hose clamp bolt Intake shutter side
Air hose No. 3 side6.0
5.361
5453 in.
lbf
47 in.
lbf
Injector driver x Engine mounting insulator RH5.55649 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay block x Radiator assy5.35447 in.
lbf
Differential pressure sensor x Body5.55649 in.
lbf
Air cleaner assy x Body x Engine mounting bracket LH7.07162 in.
lbf
Battery clamp x Body Body
Nut5.0
3.0 to 4.051
31 to 4144 in.
lbf
27 to 35 in.
lbf
Battery terminal5.45548 in.
lbf
Timing belt tensioner x Cylinder block2121415
Timing chain cover plate x Camshaft oil seal retainer9.09280 in.
lbf
Transverse engine engine mounting bracket x
Cylinder block (See page 14 −138) Bolt A
Bolt B
37
64375
65027
47
Timing belt No. 1 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 1 cover x Oil pump assy7.47565 in.
lbf
Timing belt No. 2 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 2 cover x Cylinder head cover sub −assy7.47565 in.
lbf
Timing belt No. 2 cover x Camshaft oil seal retainer7.47565 in.
lbf
Timing belt No. 2 cover x Timing belt cover No. 37.47565 in.
lbf
Crankshaft pulley x Crankshaft1801,835133
Camshaft bearing cap x Cylinder head2020415
Camshaft oil seal retainer x Cylinder head9.81007.2
Camshaft timing pulley x Camshaft8889965
Nozzle leakage pipe x Injector1616312
Nozzle leakage pipe x Camshaft bearing cap No. 42020415
Cylinder head cover x Cylinder head131359.7
Vacuum reservoir sub −assy x Cowl top panel outer8.38573 in.
lbf
Cylinder head x Cylinder block 1st
2nd3rd4th45
Turn 90 _
Turn 90 _
Turn 90 _459
Turn 90 _
Turn 90 _
Turn 90 _33
Turn 90 _
Turn 90 _
Turn 90 _
Exhaust fuel addition injector x Cylinder head1211 78.5
Drain plug (oil pan)3435025

05−84
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM1045E) DTC No.
DTC Detection ConditionTrouble Area
P0130
P0150After engine is warmed up, output voltage of heated oxygen
sensor remains at 0.4 V or more, or 0.55 V or less, during id-
ling (2 trip detection logic)
SOpen or short in heated oxygen sensor circuit
SHeated oxygen sensor (Bank1, 2 Sensor1)
SHeated oxygen sensor heater (Bank1, 2 Sensor1)
SEFI relay
SAir induction system
SFuel pressure
SInjector
SECM
P2195
P2197After engine is warmed up, output voltage of heated oxygen
sensor remains at 0.55 V or less, during idling (2 trip detection
logic)
SOpen or short in heated oxygen sensor circuit
SHeated oxygen sensor (Bank1, 2 Sensor1)
SHeated oxygen sensor heater (Bank1, 2 Sensor1)
SEFI relay
SAir induction system
SFuel pressure
SInjector
SECM
P2196
P2198After engine is warmed up, output voltage of heated oxygen
sensor remains at 0.4 V or more, during idling (2 trip detection
logic)
SOpen or short in heated oxygen sensor circuit
SHeated oxygen sensor (Bank1, 2 Sensor1)
SHeated oxygen sensor heater (Bank1, 2 Sensor1)
SEFI relay
SAir induction system
SFuel pressure
SInjector
SECM
HINT:
SBank1refers to the No.1and No. 4 cylinders.
SBank 2 refers to the No. 2 and No. 3 cylinders.
SSensor1refers to the sensor closest to the engine assembly.
SThe output voltage of the heated oxygen sensor and the short−term fuel trim value can be read using
the hand−held tester.

+25 %
−12.5 %
More than 0.5 V
Less than 0.4V
Case1
Case 2
Case 3
Case 4
Output voltage of heated oxygen
sensor (sensor1: front sensor)
Injection volume
Output voltage
Output voltage of heated oxygen
sensor (sensor 2: rear sensor)Main suspect
trouble area
OK
+25 %
−12.5 %
More than 0.5 V
Less than 0.4V
Injection volume
Output voltage
+25 %
−12.5 %
More than 0.5 V
Less than 0.4V
Injection volume
Output voltage
Sensor1: front sensor
(sensor1, heater, sensor1
circuit)+25 %
−12.5 %
More than 0.5 V
Less than 0.4V
Injection volume
Output voltage
+25 %
−12.5 %
Injection volume
Output voltage
NG
+25 %
−12.5 %
Injection volume
Output voltage
NG
+25 %
−12.5 %
Injection volume
Output voltage
NG
+25 %
−12.5 %
Injection volume
Output voltage
NGExtremely rich or lean actual
air−fuel ratio
(Injector, fuel pressure, gas
leakage in exhaust system,
etc.) OK
OK
OK
Almost no reaction


Sensor 2: rear sensor
(sensor 2, heater, sensor 2
circuit)
Almost no reaction Almost no reactionAlmost no reaction
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
05−87
AVENSIS Supplement (RM1045E)
INSPECTION PROCEDURE
HINT:
Hand−held tester only:
It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The
A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble
areas are malfunctioning or not.
(a) Perform the ACTIVE TEST A/F CONTROL operation.
HINT:
The A/F CONTROL operation lowers the injection volume12.5% or increases the injection volume 25%.
(1) Connect the hand−held tester to the DLC3 on the vehicle.
(2) Turn the ignition switch to ON.
(3) Warm up the engine by running the engine at 2,500 rpm for approximately 3 minutes.
(4) Select the item: DIAGNOSIS / OBD/MOBD / ACTIVE TEST / A/F CONTROL.
(5) Perform the A/F CONTROL operation with the engine in an idle condition (press the right or left
button).
Result:
Heated oxygen sensor reacts in accordance with increase and decrease of injection volume:
+25 %
rich output: More than 0.5 V
−12.5 %
lean output: Less than 0.4 V
NOTICE:
There is a delay of few seconds in the sensor1(front sensor) output, and there is about 20 seconds
delay at maximum in the sensor 2 (rear sensor).

05−92
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
8 CHECK AIR INDUCTION SYSTEM
(a) Check for vacuum leaks in the air induction system.
NG REPAIR OR REPLACE AIR INDUCTION SYSTEM
OK
9 CHECK FUEL PRESSURE(LOW PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP,
PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK
1 0 CHECK FUEL PRESSURE(HIGH PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP, FUEL
PRESSURE SENSOR, WIRING AND FUEL
LEAKAGE
OK
11 CONFIRM IF ANY MISFIRING DTCS WERE PRESENT AT STEP 1
(a) Misfiring DTC P0301, P0302, P0303 and/or P0304 was present at step 1.
NO REPLACE HEATED OXYGEN SENSOR
YES
1 2 REPLACE FUEL INJECTOR ASSY (See page 11−1 3)
HINT:
If one or more the misfiring DTCs P030 1, P0302, P0303 and/or P0304 were present at step 1, replace the
injector(s) mounted on the misfiring cylinder(s) that is referred by the DTC(s) with normal injector(s).
GO
13 PERFORM CONFIRMATION DRIVING PATTERN
HINT:
Clear all DTCs prior to performing the confirmation driving pattern.
GO

A01512
(V)
(3.96)
3.6
2.4
1.2
150 450
750(840)mmHg
kPa
20 60 100(112)
Manifold Absolute PressureOutput Voltage
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
05−61
AVENSIS Supplement (RM1045E)
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 standard, 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.
If the ECM detects the DTC P0105, P0107 or P0108, it operates
the fail−safe function, keeping the ignition timing and fuel injec-
tion volume constant and making it possible to drive the vehicle.
DTC No.DTC Detection ConditionTrouble Area
P0105Open or short in manifold absolute pressure sensor circuit for
0.5 second or moreSOpen or short in manifold absolute pressure sensor circuit
SManifold absolute pressure sensor
SECM
P0107Open in manifold absolute pressure sensor circuit for 0.5 se-
cond or moreSOpen or short in manifold absolute pressure sensor circuit
SManifold absolute pressure sensor
SECM
P0108Short in manifold absolute pressure sensor circuit for 0.5 se-
cond or moreSOpen or short in manifold absolute pressure sensor circuit
SManifold absolute pressure sensor
SECM
HINT:
After confirming DTC P0105, P0107 or P0108, use the hand−held tester to confirm the manifold absolute
pressure in DIAGNOSIS / OBD/MOBD / DATA LIST / ALL.
Manifold Absolute Pressure (kPa)Malfunction
Approximately 0SPIM circuit short
142 or more
SVC circuit open or short
SPIM circuit open
SE2 circuit open
05CJF−02

A00309
V1
Manifold Absolute Pressure Sensor18
E13 ECM
5V
E1
1 R
−W
33
G −W
2 3
BR 28
E2 PIM VC
VOUT
GND E13
E13
VCC
05
−62
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM1045E)
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
S If DTCs related to different systems that have terminal E2 as the ground terminal are output simulta-
neously, terminal E2 may have an open circuit.
S Read freeze frame data using the hand−held tester . Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the
vehicle was running or stopped, if the engine was warmed up or not, if the air −fuel ratio was lean or
rich, and other data from the time the malfunction occurred.
1 READ VALUE OF HAND −HELD TESTER(INTAKE MANIFOLD ABSOLUTE
PRESSURE)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the hand −held tester ON.
(d) On the hand −held tester, select the item: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / MAP.
(e) Read the values.
Pressure: Same as the atmospheric pressure
Result:
Manifold Absolute Pressure (kPa)Proceed to
142 or moreA
0.0B
OK (Same as actual atmospheric pressure) (*1)C
*1: The value must be changed when the engine is run or stopped.
B Go to step 3
C CHECK FOR INTERMITTENT PROBLEMS(See Page 05 −7)
A