2005 TOYOTA AVENSIS fuel pressure

A81017
Generator (Alternator)Glow Plug
ECM
Glow
Plug
Relay
Battery
Duty Ratio
05
−426
−
DIAGNOSTICS ECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
DTC P0622 GENERATOR FIELD ”F” TERMINAL CIRCUIT
CIRCUIT DESCRIPTION
While the generator (alternator) is generating current, a duty ratio is sent from terminal M of the generator
to the ECM terminal ALT. This duty ratio is used for detecting an open malfunction of the generator circuit
and DTC P0380.
HINT:
DTC P0380 is prepared for indicating an open or short malfunction in the glow plug circuit. If this DTC is de-
tected, inspect the glow plug circuit. (See page 05 −386)
DTC No.DTC Detection ConditionTrouble Area
P0622
No duty ratio from terminal M of the generator (alternator) at
the engine running
(1 trip detection logic)SOpen in generator (alternator) circuit
S Generator (alternator)
S Drive belt
S ECM
HINT:
After confirming DTC P0622, check the internal fuel pressure of the common rail in the ”DIAGNOSIS / OBD/
MOBD / DATA LIST / ALL / GENERATOR” using the hand −held tester.
Result:
Engine SpeedGenerator Duty Ratio (%)
Idling10 to 100
When increasing engine speedGenerator duty ratio drops
When decreasing engine speedGenerator duty ratio rises
MONITOR DESCRIPTION
The ECM will detect a generator (alternator) failure or an open malfunction of the circuit, if the duty ratio is
not output from terminal M of the generator (alternator) despite running the engine.
MONITOR STRATEGY
Required SensorsGenerator (alternator) circuit
Frequency of operationContinuous
Duration10 seconds
CHK ENG Operation1 driving cycle
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
Battery voltage11 V−
Engine speed700 rpm2,000 rpm
05DW0 −02

A84701
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketzGasketFuel Tube Sub−assy
Fuel Pipe
Clamp
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy
zFuel Pump
Insulator
Fuel HoseFuel Pipe Sub−assy No. 1
zFuel Injector Back−up Ring No. 1
zFuel Injector Back−up Ring No. 2
zFuel Injector Back−up Ring No. 3
25 (255, 18)x2
zO−ring
9.0 (92, 80 in.
lbf)
30 (306, 22)
x2
33 (331, 24)
− ENGINE CONTROL SYSTEMKNOCK SENSOR (2AZ−FSE)
10−13
AVENSIS Supplement (RM1045E)

A84709
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part zIntake Manifold
to Head Gasket No. 1Vacuum Hose
Pressure Sensor
Connector Intake Air Control Valve AssyVSV
ConnectorzIntake to Exhaust
Manifold Gasket Manifold Insulator No. 1
Charcoal Canister
Outlet Hose No. 1
Fuel Hose No. 1
Charcoal Canister
AssyIntake Manifold Vacuum Hose Vacuum Sensor
Connector
Vacuum Sensor
AssyVentilation Hose No. 1
30 (306, 22)
x2
30 (306, 22)
30 (306, 22)
9.5 (97, 84 in.
lbf)x2
x3
5.5 (56, 49 in.
lbf)
10−14
− ENGINE CONTROL SYSTEMKNOCK SENSOR (2AZ−FSE)
AVENSIS Supplement (RM1045E)

A88251N·m (kgf·cm, ft·lbf)
: Specified torqueKnock Sensor
Knock Sensor
Connector
Intake Manifold Insulator No. 2
Surge Tank Stay No. 1
x2 Fuel Injector
ConnectorFuel Pressure Sensor
Connector
20 (204, 15)
21 (210, 15)
9.8 (100, 7)
− ENGINE CONTROL SYSTEMKNOCK SENSOR (2AZ−FSE)
10−15
AVENSIS Supplement (RM1045E)

A86430
New Gasket
Hollow Screw
SST
A09663
:Seal Packing
11
−50
−
FUEL INJECTOR ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(c) Tighten the 4 hollow screws and bolt by hand.
(d) Tighten the 4 hollow screws and bolt. Torque:
16 N
m (163 kgf
cm, 12 ft
lbf) for hollow screw
20 N
m (204 kgf
cm, 15 ft
lbf) for flange bolt
NOTICE:
In any case, when the torque exceeds the upper limit, re-
place the leakage pipe hollow screw and gaskets with new
ones.
(e) Check that there are no leaks from the nozzle leakage
pipe connection.
(1) Apply a light coat of soapy water (any fluid to detect fuel leaks) to the nozzle leakage pipe connection.
(2) Using SST (a turbocharger pressure gauge), attach SST to the fuel return side of the nozzle leakage
pipe, then maintain 100 kPa (1.0 kgf/cm
2 , 14.5 psi)
of pressure for 60 seconds to check that there are
no bubbles from the pipe connection.
SST 09992 −00242
(3) After checking fuel leaks, wipe off soapy water from
the pipe connection.
21. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head. Seal packing: Part No. 08826 −00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.8 ft
lbf)
22. INSTALL NOZZLE LEAKAGE PIPE NO.2
(a) Install the nozzle leakage pipe No. 2 with the 2 bolts. Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
(b) Connect the 2 fuel hoses.
23. INSTALL NOZZLE HOLDER SEAL
(a) Install new 4 nozzle holder seals.
24. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)

11−54
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
34. CHECK FOR FUEL LEAKS
NOTICE:
Under the ACTIVE TEST mode, the fuel pressure increases. Take precautions to prevent fuel from
spraying on you or inside the engine compartment.
HINT:
During the ACTIVE TEST mode, engine speed goes high and combustion noise becomes loud.
(a) Check that there are no fuel leaks from any parts of the fuel system when the engine is not running.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(b) While cranking or when starting the engine, check that there is no leaks from any parts of the fuel sys-
tem.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(c) Disconnect the fuel hose from the common rail.
(d) While cranking the engine, check fuel leaks from the return pipe.
HINT:
If there is fuel leakage, replace the common rail.
(e) Connect the hand−held tester to the DLC3.
(f) Start the engine, then turn the hand−held tester ON.
(g) Select the FUEL LEAK test of the ACTIVE TEST mode on the hand−held tester.
(h) If you do not have the hand−held tester, depress the accelerator pedal quickly and fully to increase
the engine speed to its maximum, then keep it for 2 seconds. Repeat this operation several times.
(i) Check that there are no leaks from any parts of the fuel system.
NOTICE:
If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in a minute, it is acceptable.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(j) Reconnect the fuel hose to the common rail.

A84701
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketzGasketFuel Tube Sub−assy
Fuel Pipe
Clamp
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy
zFuel Pump
Insulator
Fuel HoseFuel Pipe Sub−assy No. 1
zFuel Injector Back−up Ring No. 1
zFuel Injector Back−up Ring No. 2
zFuel Injector Back−up Ring No. 3
25 (255, 18)x2
zO−ring
9.0 (92, 80 in.
lbf)
30 (306, 22)
x2
33 (331, 24)
− FUELFUEL PUMP ASSY (2AZ−FSE)
11−23
AVENSIS Supplement (RM1045E)

1111 4−01
A88253
(a)
(b)
Pull Out
A88252
(a)
(b)
(c)
(d)
A77920
RHD:
LHD:
−
FUEL FUEL INJECTOR ASSY (2AZ −FSE)
11 −13
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11 −1)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 10 −8)
3. REMOVE ENGINE ROOM COVER SIDE (See page 10 −8)
4. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
5. DRAIN ENGINE COOLANT (See page 16 −7)
6. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 10 −8)
7. REMOVE AIR CLEANER CAP SUB −ASSY (See page 10 −8)
8. REMOVE THROTTLE BODY ASSY (See page 10 −8)
9. REMOVE FUEL TUBE SUB −ASSY (See page 11 −24)
SST 09617 −24011
10. REMOVE FUEL HOSE (See page 11 −24)
11. REMOVE FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
12. REMOVE FUEL PUMP ASSY (See page 11 −24)
13. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the fuel hose from the charcoal canister hose.
(b) Disconnect the charcoal canister outlet hose No. 1 from the charcoal canister.
(c) Pull out the charcoal canister from the charcoal canister base bracket.
14. REMOVE VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE)
(a) Remove the wiring harness clamp.
(b) Disconnect the vacuum sensor connector.
(c) Disconnect the vacuum hose from the vacuum sensor.
(d) Remove the bolt, then remove the vacuum sensor.
15. REMOVE INTAKE MANIFOLD
(a) Disconnect the union to connector tube hose from the
brake booster.