2005 TOYOTA AVENSIS fuel

05±546
±
DIAGNOSTICS ECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E) P0380
(05±622)
Glow Plug/Heater Circuit ºAº

Open or short in glow plug circuit

Glow fuse

Glow relay

Glow plug

ECM

P0400
(05±629)Exhaust Gas Recirculation Flow
EGR valve assy

EGR passage
P0403
(05±629)Exhaust Gas Recirculation Con-
trol Circuit
EGR assage

Open or short in EGR circuit

ECM
P0488
(05±633)Exhaust Gas Recirculation
Throttle Position Control Range/
Performance
Open or short in intake shutter circuit

Open or short in fully opened switch circuit

Intake shutter

ECM

P0500
(05±640)Vehicle Speed Sensor ºAº

Open or short in speed sensor circuit

Speed sensor

Combination meter

ECM

Skid control ECU

P0504
(05±643)Brake Switch ºAº/ºBº Correlation

Short in stop lamp switch signal circuit

Stop lamp switch

ECM


P0560
(05±647)System Voltage
Open in back±up power source circuit

ECM
P0606
(05±650)ECM/PCM Processor

ECM



P0607
(05±650)Control Module Performance

ECM

P0622
(05±651)Generator Field ºFº Terminal Cir-
cuit

Open in generator circuit

Generator

Drive belt

ECM

P0627
(05±655)Fuel Pump Control Circuit / Open

Open or shot in suction control valve circuit

Suction control valve

ECM

P1229
(05±563)Fuel Pump System

Short in supply pump (suction control valve) circuit

Suction control valve

ECM

P1238
(05±658)Injector Malfunction

Injector

EDU (P0200 is set simultaneously)

Open or short in engine wire (P0200 is set simultaneously)

Connector connection (P0200 is set simultaneously)

Compression pressure

Valve clearance

Valve timing

ECM

P1251
(05±612)Turbo/Super Charger Overboost
Condition (Too High)

VRV

Open or short in VRV circuit

Turbocharger

EGR valve

Vacuum hose

ECM

P1271
(05±663)Fuel Regulator Circuit Malfunc-
tion (EDU Drive)

Open or short in pressure discharge valve circuit

Open or short in pressure discharge valve it self

EDU

ECM

P1272
(05±663)Fuel Pressure Regulator Mal-
function

Open or short in pressure discharge valve circuit (P1271 is set
simultaneously)

Pressure discharge valve

Supply pump

ECM


3 2 1 45678
9 1 0 111 21 31 41 51 6
DLC3
A04550
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±529
AVENSIS REPAIR MANUAL (RM1018E)

* 2 trip detection logic
When a logic malfunction is first detected, the pend-
ing fault code is stored in the ECM memory (1st trip).
If the same malfunction is detected again during the
second drive test, this second detection causes the
CHK ENG to illuminate (2nd trip) (However, the igni-
tion switch must be turned OFF between the 1st trip
and 2nd trip).

Freeze frame data:
The freeze frame data records the engine condi-
tions (fuel system, calculator load, engine coolant
temperature, engine speed, vehicle speed, etc.)
when the malfunction is detected. When trouble-
shooting, it is useful for determining whether the ve-
hicle was running or stopped, the engine was
warmed up or not, etc. at the time of the malfunc-
tion.

Priorities for troubleshooting:
If troubleshooting priorities for multiple DTCs are
given in the applicable DTC chart, these should be
followed.
(b) Check the DLC3.
The vehicle's ECM uses the ISO 9141±2(Euro±OBD)
communication protocol. The terminal arrangement of
the DLC3 complies with ISO 15031±03 and matches the
ISO 9141±2 format.
Terminal No.Connection / Voltage or ResidenceCondition
7Bus + Line / Pulse generation+During transmission
4Chassis Ground ± Body Ground / 1
or lessAlways
16Battery Positive ± Body Ground / 9 to 14 VAlways
HINT:
If the display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the hand±held tester to
the DLC3, turned the ignition switch ON and operated the
hand±held tester, there is a problem on the vehicle side or tool
side.

If communication is normal when the tool is connected to
another vehicle, inspect the DLC3 on the original vehicle.

If communication is still impossible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Deparment listed in the
tool's instruction manual.

05±532
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Clearing the DTCs not using the hand±held tester:
(1) Disconnect the battery terminal or remove the EFI
and ETCS fuses from the engine room R/B for more
than 60 seconds.
4. FAIL±SAFE CHART
If any of the following codes are recorded, the ECM enters the fail±safe mode.
DTC No.Fail±Safe OperationFail±Safe Deactivation Conditions
P0087VTA is fixed at 10 %Ignition switch OFF
P0088VTA is fixed at 10 %Ignition switch OFF
P0093After fail safe driving control is performed for 1 minute, en-
gine stallsIgnition switch OFF
P0095
P0097
P0098
Intake air temp. is fixed at 145
C (293
F)Return to normal condition
P0105
P0107
P0108
Turbo pressure is set at fixed valueReturn to normal condition
P0115
P0117
P0118
When fuel temp. sensor operates normal and intake air
temp. is less than 15
C (59
F), value of fuel temp. sensor
is substituted
When fuel temp. sensor operates normal and intake air
temp. is more than 20
C (68
F), value is fixed at 120
C
(248
F)
When the fuel temp. sensor is abnormal, value is fixed at
40
C (104
F)
Return to normal condition
P0168Output limitReturn to normal condition
P0180
P0182
P0183
Fuel temp. is fixed at 40
C (104
F)Return to normal condition
P0190
P0191
P0192
P0193
VTA is fixed at 10 %Ignition switch OFF
P0200VTA is fixed at 25 %Ignition switch OFF
P0335Output limitReturn to normal condition
P0488VTA is fixed at 25 %Ignition switch OFF
P0500Vehicle speed is fixed at 0 km/h (0 mph)Vehicle speed less than 10 km/h (6 mph)
P1229VTA is fixed at 10 %Ignition switch OFF
P1271VTA is fixed at 25 %Ignition switch OFF
P1272VTA is fixed at 25 %Ignition switch OFF
P2120
P2122
P2123
P2125
P2127
P2128
P2138
Output limitIgnition switch OFF
5. CHECK FOR INTERMITTENT PROBLEMS
Hand±held tester only:
By putting the vehicle's ECM in the check mode, the 1 trip detection logic is possible instead of the 2 trip
detection logic, and the sensitivity to detect faults is increased. This makes it easier to detect intermittent
problems.
(a) Clear the DTCs (See step 2).
(b) Set the check mode (See step 3).

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±533
AVENSIS REPAIR MANUAL (RM1018E)
(c)Perform a simulation test (See page 01±22).
(d)Check the connector and terminal (See page 01±32).
(e)Wiggle the harness and connector (See page 01±32).
6. DATA LIST
HINT:
Using the DATA LIST displayed by the hand±held tester, you can read the value of the switches, sensors,
actuators and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one
method to shorten diagnostic time.
NOTICE:
The values given below for ºNormal Conditionº are representative valu\
es. A vehicle may still be nor-
mal even if its value differs from those listed here. Do not solely depend \
on the ºNormal Conditionº
here when deciding whether a part is faulty or not.
(a) Warm up the engine.
(b) Turn the ignition switch OFF.
(c) Connect the hand±held tester to the DLC3.
(d) Turn the ignition switch ON.
(e) Push the ºONº button of the hand±held tester.
(f) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LISTº.
(g) According to the display on tester, read the ºDATA LISTº.
Hand±held Tester DisplayMeasurement Item/Range
(Display)Normal Condition *Diagnostic Note
INJ VOLUMEInjection volume/
Min.: 0 mm3, Max.: 1279.98 mm3Idling: 3 to 10 mm3

INJ TIMINGInjection timing/
Min.: 0 CA, Max.: 51 CAIdling: ±1 to 5 CA

ENGINE SPDEngine speed/
Min.: 0 rpm, Max.: 16383.75 rpmIdling: 750 to  rpm

MAF
Air flow rate from MAF sensor sta-
tus/
Min.: 0 gm/s, Max.: 655.35 gm/s
Idling: 3.2 to 4.7 gm/s

Running without load (2,500
rpm): 13.1 to 18.9 gm/s
If the value is Approximately 0.0
gm/s:

Mass air flow meter power
source circuit open

VG circuit open or short
If the valve is 160 gm/s or more:

E2G circuit open
PIM
Absolute pressure inside intake
manifold/ Min.: 0 kPa, Max.: 255
kPa
Idling: 85 to 110 kPa

COOLANT TEMPCoolant temperature/
Min.: ±40 C, Max.: 215 CAfter warming up: 80 to 95 C (176
to 203 

INTAKE AIRIntake air temperature/
Min.: ±40 C, Max.: 215 CEquivalent to Ambient Temp.
If the value is º±40 Cº or º140
 Cº, sensor circuit is open or
shorted
FUEL TEMPFuel temperature status/
Min.: ±40 C, Max.: 215 CActual fuel temp.
shorted.
ACCEL POSITIONAccel position status/
Min.: 0 %, Max.: 100 %

Accelerator pedal released:
10 to 22 %

Accelerator pedal depressed:
52 to 90 %
Read the value with ignition switch
ON (Do not start engine).
VEHICLE SPDVehicle speed/
Min.: 0 km/h, Max.: 255 km/hActual vehicle speedSpeed indicated on speedometer
THROTTLE POSThrottle step position status/
Min.: 1 step, Max.: 255 step
Throttle fully closed: 1 step

Throttle fully open: 255 stepRead the value with ignition switch
ON (Do not start engine).
COMN RAIL PRESSCommon rail pressure status/
Min.: 0 MPa, Max.: 255 MPaIdling: 30 to 40 MPa

± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±535
AVENSIS REPAIR MANUAL (RM1018E)
(g) According to the display on tester, perform the ºACTIVE TESTº.
Hand±held Tester DisplayTest DetailsDiagnostic Note
EGR STEP POS
[Test Details]
Change step of EGR motor
Min: 0 step, Max: 125 step


TC/TE1
[Test Details]
Connect the TC and TE1
ON or OFF


FUEL LEAK TEST
[Test Details]
Fuel leak test
ON or OFF


INJECTOR CUT #1
[Test Details]
Injector cut #1
ON or OFF


INJECTOR CUT #2
[Test Details]
Injector cut #2
ON or OFF


INJECTOR CUT #3
[Test Details]
Injector cut #3
ON or OFF


INJECTOR CUT #4
[Test Details]
Injector cut #4
ON or OFF

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±543
AVENSIS REPAIR MANUAL (RM1018E)
4CHECK FUEL QUALITY
(a)Check that only diesel fuel is used
(b)Check that the fuel does not contain any impurity.
NGREPLACE FUEL
OK
5CHECK ENGINE OIL (See page 17±20)
NGADD OR REPLACE
OK
6CHECK ENGINE COOLANT (See page 16±37)
NGREPLACE ENGINE COOLANT (See page 16±44)
OK
7CHECK IDLE SPEED AND MAXIMUM SPEED (See page 14±266)
NGREPAIR OR REPLACE INJECTION PUMP (See page 11±69)
OK
8CHECK DIAGNOSTIC CIRCUIT
NGREPAIR OR REPLACE
OK
9CHECK VACUUM PUMP
NGREPAIR OR REPLACE VACUUM PUMP
OK
PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE (See page 05±551)

05CPA±01
05±526
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
PRECAUTION
1. Since each injector has a characteristic fuel injecting behavior, the ECM compensates such be-
havior by adjusting an injection time for each injector to optimize the fuel injection volume.
Compensating data for the optimum injection volume, which has converted into a 30±digit±al-
phanumeric value, has been imprinted on a head potion of the injector as the injection com-
pensation code.
2. The injection compensation code will be required to register to the ECM when replacing the in-
jectors or the ECM.
3. If an incorrect injection compensation value was registered to the ECM, the engine assembly
may rattle or the engine idling may be rough. In addition, it may be a cause of the engine failure
or short±life.

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.