2005 TOYOTA AVENSIS fuel

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.

A81480
Plunger A: Pumping End
Plunger B: Suction EndPlunger A: Suction Start
Plunger B: Pumping Start Check Valve
Eccentric Cam
Ring Cam
Plunger B
Plunger A
Plunger A: Pumping Start
Plunger B: Suction StartPlunger A: Suction End
Plunger B: Pumping End Supply Pump Operation Diagram
From
Feed Pump
To Common Rail Suction
Control
Valve
05±520
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
4. SUPPLY PUMP OPERATION SYSTEM
The rotation of the eccentric cam causes the ring cam pushes plunger A upward as illustrated below. The
spring force pulls plunger B (which is located on opposite of plunger A) upward. As a result, plunger B draws
fuel in, and plunger A pumps fuel at the same time.

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
(
)
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

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±597
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0116ENGINE COOLANT TEMPERATURE CIRCUIT
RANGE/PERFORMANCE PROBLEM
CIRCUIT DESCRIPTION
Refer to DTC P0115 on page 05±593.
DTC No.DTC Detection ConditionTrouble Area
P0116
When THW greater than ±40 \fC (±40 \fF) and less than 60 \fC
(140 \fF), and THA greater than ±6.7 \fC (20 \fF), and when start-
ing engine, conditions (a) and (b) continue (2 trip detection
logic):
(a)Vehicle speed is changing (Not stable)
(b)THW change is lower than 3 \fC (5.4 \fF) after engine was
started.

Cooling system

Engine coolant temperature sensor

Thermostat
In case that reading value of engine coolant temp. sensor will
not change more than 1 \fC (1.8 \fF) even after repeating 6 trips
(detection logic) of adjusting speed pattern with THW more
than 90 \fC (194 \fF) after engine was started.
INSPECTION PROCEDURE
HINT:

If DTCs ºP0115, P0116, P0117and P0118º are output simultaneously, engine coolant temperature
sensor circuit may be open or short. Perform the troubleshooting of DTC ºP0\
115, P0117 or P0118º first.

Read freeze frame data using \b
 . Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, it is useful for d\
etermining whether the vehicle
was running or stopped, the engine was warmed up or not, the air±fuel ra\
tio was lean or rich, etc. at
the time of the malfunction.
1CHECK OTHER DTC OUTPUT(BESIDES DTC P0116)
(a)Read the DTC using the hand±held tester. Result:
Display (DTC output)Proceed to
Only P0116 are outputA
P0116 and other DTCs are outputB
HINT:
If any other codes besides ºP0116º are output, perform the troubleshooting for those DTCs first.
BGO TO RELEVANT DTC CHART(See page 05±544)
A
2INSPECT THERMOSTAT (See page 16±39)
NGREPLACE THERMOSTAT (See page 16±50)
OK
REPLACE ENGINE COOLANT TEMPERATURE SENSOR
05CPN±01

± 20 0 20 40 60 80 100
(± 4) 32 68 104 140 176 212 30
20
10
5
3
2
1
0.5
0.3
0.2
0.1
A67628
Acceptable (Fig.1)
Resistance K

Temp. C (F)
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±589
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0110 INTAKE AIR TEMPERATURE CIRCUIT
DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW
INPUT
DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH
INPUT
CIRCUIT DESCRIPTION
The intake air temperature sensor is built in the mass air flow
meter and senses the intake air temperature.
A thermistor built in the sensor changes the resistance value
according to the intake air temperature.
The lower the intake air temperature is, the greater the thermis-
tor resistance value becomes, and the higher the intake air tem-
perature is, the lower the thermistor resistance value becomes
(See Fig. 1).
The intake air temperature sensor is connected to the ECM
(See below ). The 5 V power source voltage in the ECM is ap-
plied to the intake air temperature sensor from terminal THA
(THAR) via resistor R.
The resistor R and the intake air temperature sensor are con-
nected in series. When the resistance value of the intake air
temperature sensor changes in accordance with changes in the
intake air temperature, the potential at terminal THA (THAR)
also changes. Based on this signal, the ECM increases the fuel
injection volume to improve the driveability with a cold engine.
DTC No.Proceed toDTC Detection ConditionTrouble Area
P0110Step 1
Open or short in intake air
temp. sensor circuit for 0.5
sec. (1 trip detection logic)
P0112Step 4
Short in intake air temp. sen-
sor circuit for 0.5 sec.
(1 trip detection logic)
Open or short in intake air temperature sensor circuit

Intake air temperature sensor (built in mass air flow meter)

ECM
P0113Step 2
Open in intake air temp. sen-
sor circuit for 0.5 sec.
(1 trip detection logic)
HINT:
After confirming DTC ºP0110, P0112 or P0113, use the hand±held tester to confirm the intake air tempera-
ture from the ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALLº.
Temperature DisplayedMalfunction
±40C (±40Open circuit
140C (284  Short circuit
05CPL±01

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