2005 TOYOTA AVENSIS catalytic converter

05−302
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P0606
(05 −425)ECM/PCM Processor
ECM



P0607
(05 −425)Control Module Performance
SECM
ff
P0622
(05 −426)Generator Field ”F” Terminal Cir-
cuit
SOpen in generator (alternator) circuit
S Generator (alternator)
S Drive belt
S ECM
ff
P0627
(05 −429)Fuel Pump Control Circuit / Open
SOpen or shot in suction control valve circuit
S Suction control valve
S ECM
ff
P 1229
(05 −32 1)Fuel Pump System
S Short in supply pump (suction control valve) circuit
S Supply pump (suction control valve)
S ECM
ff
P 1238
(05 −43 1)Injector Malfunction
S Injector
S EDU (P0200 is set simultaneously)
S Open or short in engine wire harness (P0200 is set simulta-
neously)
S Connector connection (P0200 is set simultaneously)
S Compression pressure
S Valve clearance
S Valve timing
S ECM
ff
P 125 1
(05 −376)Turbo/Super Charger Overboost
Condition (Too High)
SVRV
S Open or short in VRV circuit
S Turbocharger
S EGR valve
S Vacuum hose
S ECM
ff
P 127 1
(05 −435)Fuel Regulator Circuit Malfunc-
tion (EDU Drive)
SOpen or short in pressure discharge valve circuit
S Open or short in pressure discharge valve itself
S EDU
S ECM
ff
P 1272
(05 −435)Fuel Pressure Regulator Mal-
function
SOpen or short in pressure discharge valve circuit (P 127 1is set
simultaneously)
S Pressure discharge valve
S Supply pump
S ECM
ff
P 1386
(05 −444)Injector For Exhaust Fuel Addi-
tion
SOpen or short in exhaust fuel addition injector circuit
S Exhaust fuel addition injector
S DPNR catalytic converter (Manifold converter sub −assy)
S Open in exhaust temperature sensor circuit
S A/F sensor
S Exhaust gas temperature sensor
S Supply pump assy
S Mass air flow meter
S Fuel leaks in exhaust fuel addition injector
S Main injector
S Cylinder compression pressure
S Valve clearance
S Valve timing
S Air intake system has blockages
S Air intake system has leakage
S Exhaust system has blockages
S Exhaust system has leakage
S EGR system has blockages
S EGR system has leakage
S ECM
ff

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −303
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P 1425
(05 −457)Differential Pressure Sensor Cir-
cuit
SOpen or short in differential pressure sensor circuit
S Incorrect arrangement differential pressure sensor hose piping
S Differential pressure sensor
S ECM
ff
P 1426
(05 −462)Differential Pressure Sensor
(Installation)
SIncorrect arrangement differential pressure sensor hose piping
S Differential pressure sensor vacuum hose is clogged
S Blockage in vacuum transmitting pipe sub −assy
S Differential pressure sensor
S ECM
ff
P 1427
(05 −457)Differential Pressure Sensor Cir-
cuit LowSOpen or short in differential pressure sensor circuit
S Incorrect arrangement differential pressure sensor hose pipingff
P 1428
(05 −457)Differential Pressure Sensor Cir-
cuit High
Incorrectarrangementdifferentialpressuresensorhosepiping
SDifferential pressure sensor
S ECMff
P 160 1
(05 −465)Injector Correction Circuit Mal-
function (EEPROM)SInjector compensation code
S ECMff
P 1611
(05 −425)IC Circuit MalfunctionSECMff
P2002
(05 −466)Particulate Trap Efficiency Below
Threshold (Bank 1)
SDPNR catalytic converter (manifold converter sub −assy)
S Differential pressure sensor
S Differential pressure sensor vacuum hose is clogged
S Blockage in vacuum transmitting pipe sub −assy
S Exhaust gas temperature sensor
S Exhaust gas leaks in TOYOTA D −CAT
S Mass air flow meter
S ECM
ff
P203 1
(05 −415)Exhaust Gas Temperature Sen-
sor Circuit (Bank 1Sensor 2)ff
P2032
(05 −415)Exhaust Gas Temperature Sen-
sor Circuit Low (Bank 1Sensor
2)S Open or short in exhaust gas temperature sensor (on down
stream) circuit
S Exhaust gas temperature sensor (on down stream)
ff
P2033
(05 −415)Exhaust Gas Temperature Sen-
sor Circuit High (Bank 1Sensor
2)
gp()
S ECM
ff
P2047
(05 −470)Reductant Injector Circuit/Open
(Bank 1Unit 1)SOpen in exhaust fuel addition injector circuit
S Exhaust fuel addition injector
S ECM
ff
P2 120
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D” CircuitSOpen or short in accelerator pedal position sensor circuit
S Accelerator pedal position sensor
S ECM
ff
P2 121
(05 −479)Throttle/Pedal Position Sensor/
Switch ”D” Circuit Range/Perfor-
manceSAccelerator pedal position sensor circuit
S Accelerator pedal position sensor
S ECM
ff
P2 122
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D” Circuit Low Inputff
P2 123
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D” Circuit High Inputff
P2 125
(05 −473)Throttle/Pedal Position Sensor/
Switch ”E” Circuit
SOpen or short in acceleratorpedalposition sensor circuitff
P2 127
(05 −473)Throttle/Pedal Position Sensor/
Switch ”E” Circuit Low Input
SOpenorshortinacceleratorpedalpositionsensorcircuit
SAccelerator pedal position sensor
S ECMff
P2 128
(05 −473)Throttle/Pedal Position Sensor/
Switch ”E” Circuit High Inputff
P2 138
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D”/”E” Voltage Correla-
tion
ff

05I7Z−01
A91210
Engine Control System Diagram:
Accelerator Pedal
Position Sensor
Ignition Switch Signal
Starter Signal
Vehicle Speed Signal
DLC3Supply Pump
Pressure Discharge Valve Fuel Pressure Sensor
EDU Relay
EDU
Atmospheric
Temperature
Sensor
Glow
Plug Relay
Crankshaft Position SensorCamshaft
Position
SensorCommon Rail Suction Control Valve
Alternator Duty SignalDCAT Switch
ECM
Atmospheric
Pressure
Sensor
A/F Sensor Heater
Mass Air Flow Meter
Differential
Pressure Sensor
A/F Sensor Actuator
E−VRV
Exhaust Gas Temperature Sensor
(Up Stream)
Exhaust Gas Temperature Sensor
(Down Stream)Glow Plug EGR Valve
Injector
Turbo Pressure
Sensor
Engine Coolant
Temperature Sensor
Intake Air
Temperature
Sensor
Fuel Temperature Sensor
EGR Cooler Inter Cooler
Exhaust Fuel
Addition
Injector
DPNR Catalytic Converter
Turbocharger
(INJT and PRD Signal)
(INJF Signal)
Intake Shutter
(Throttle Valve)
Oxidation Catalytic
Converter
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−255
AVENSIS Supplement (RM1045E)
SYSTEM DESCRIPTION
1. ENGINE CONTROL SYSTEM

A85344
TOYOTA D−CAT Diagram:
DCAT
Switch
EDU
ECM
Common RailInjector
Fuel Tank EGR Valve
FReduces NOx (Linear Solenoid Type)EGR Cooler
FCools Down EGR GasExhaust Fuel Addition
Injector
FReduces NOxEGR Cooler Catalyst
FMaintains proper operation of EGR cooler
Differential Pressure
Sensor
Exhaust Gas
Temperature Sensor
FMonitors catalyst
A/F Sensor
Oxidation Catalytic Converter
FReduces HC and CO Manifold Converter Sub−assy
(DPNR Catalytic Converter)
FReduces NOx, PM, HC, and CO Intake Shutter (Throttle Valve)
Supply Pump
FSupplies fuel to exhaust fuel addition injector
temperature FDPNR catalyst regeneration
FSupplies high pressure fuel to main injector via common rail
Pressure Discharge Valve
Fuel Pressure sensor
05−256
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
2. TOYOTA D−CAT DESCRIPTION
(a)TOYOTA D−CAT:
Diesel Clean Advanced Technology (TOYOTA D−CAT) comprehensively regulates engine control (consists
of a catalytic system and a fuel injection system) that purifies both particulate matter (PM) and nitrogen ox-
ides (NOx) discharged by diesel engines.
The catalytic system purifies hydrocarbons (HC) and carbon monoxides (CO), and reduces PM and NOx
with a catalytic converter with the Diesel Particulate−NOx Reduction system (DPNR). The fuel injection sys-
tem adds fuel into the exhaust port using the exhaust fuel addition injector to produce RICH state for NOx
reduction and maintain a proper catalyst temperature for DPNR catalyst regeneration.

− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−257
AVENSIS Supplement (RM1045E)
(b)TOYOTA D−CAT COMPONENTS:
ComponentDescription
DPNR catalytic converterReduces HC, CO, PM, and NOx.
Exhaust fuel addition in-
jectorAdds fuel into the exhaust port in order to produce RICH air−fuel ratio for NOx reduction. Also, raises catalyst temper-
ature for DPNR catalyst regeneration.
Exhaust gas temperature
sensorUsed for estimating DPNR catalytic converter temperature and adjusting fuel addition by ECM while DPNR catalyst
regeneration is performed. Also, detects DPNR catalytic converter temperature to prevent the catalytic converter
temperature from rising too high.
Differential pressure sen-
sorDetects the volume of PM deposits in and incorrect vacuum hose arrangement on the DPNR catalytic converter.
A/F sensorUsed for controlling air−fuel ratio. By controlling the air−fuel ratio, combustion control for low temperature combustion
and DPNR catalyst regeneration are properly regulated.

DTC No.
( ): Potential DTCs
( F )
ABCDE F G HI JKL MNOPQ RS T
P003 1 (See page 05 −305)
P0544 (See page 05 −415)
P0545 (See page 05 −415)
P0546 (See page 05 −415)
P 1386 (See page 05 −444)
P 1425 (See page 05 −457)
P 1426 (See page 05 −462)
P 1427 (See page 05 −457)
P 1428 (See page 05 −457)
P2002 (See page 05 −466)
P203 1 (See page 05 −415)
P2032 (See page 05 −415)
P2033 (See page 05 −415)
P2047 (See page 05 −470)
P2238 (See page 05 −484)
P2239 (See page 05 −484)
F
F
F F
F
F FF
FF F F FFF
FF
F
F
F
F FF
F
F
F
F F F
F
F
F
FFF
F (
F )(F)
( F )
(F )(F )(F ) (
F )(F )
( F )
F
F
F F
F
F
(F )(
F )
( F )
( F )(
F )
F F F
F
( F )
( F )(F)( F)
05
−258
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
(c) DIAGNOSTICS TROUBLE CODES (DTCS) TABLE FOR TOYOTA D −CAT:
HINT:
This table indicates typical DTC combinations for each malfunction occurrence.
Trouble AreaMalfunctionRefer to
DPNR catalytic converterDeteriorated or cloggedA
Stuck openB
Stuck closeC
Eha stfeladditioi jectoLow fuel addition volumeDExhaust fuel addition injectorOpen in exhaust fuel addition injector circuitE
Short in exhaust fuel addition injector circuitF
Open or short in exhaust fuel addition injectorG
Open in exhaust gas temperature sensor circuitH
Exhaust gas temperature sensorShort in exhaust gas temperature sensor circuitIExhaustgastemperaturesensor
Exhaust gas temperature sensorJ
Open in differential pressure sensor circuitK
Short in differential pressure sensor circuitL
DifferentialpressuresensorDifferential pressure sensorMDifferential pressure sensorDifferential pressure sensor cloggedN
Incorrect vacuum hose arrangement of the differ-
ential pressure sensorO
A/Fse soOpen or short in A/F sensor or heater circuitPA/F sensorA/F sensorQ
Exhaust gas leaksExhaust gas leaksR
Fuel leaksFuel leaks in fuel addition injectorS
Supply pumpCorrect fuel pressure cannot be fed to the ex-
haust fuel addition injectorT

− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−259
AVENSIS Supplement (RM1045E)
(d)DIAGNOSTICS TROUBLE CODE DESCRIPTION FOR TOYOTA D−CAT:
DTC No.Description
P0031Open or short in A/F sensor or heater circuit (Low output)
P0544Open or short in exhaust gas temperature sensor circuit (Up stream)
P0545Open or short in exhaust gas temperature sensor circuit (Up stream) (Low output)
P0546Open or short in exhaust gas temperature sensor circuit (Up stream) (High output)
P1386TOYOTA D−CAT fuel addition system malfunction
P1425Open or short in differential pressure sensor circuit
P1426Differential pressure sensor is clogged or has incorrect vacuum hose arrangement
P1427Open or short in differential pressure sensor circuit (Low output)
P1428Open or short in differential pressure sensor circuit (High output)
P2002DPNR Catalytic converter malfunction
P2031Open or short in exhaust gas temperature sensor circuit (Down stream)
P2032Open or short in exhaust gas temperature sensor circuit (Down stream) (Low output)
P2033Open or short in exhaust gas temperature sensor circuit (Down stream) (High output)
P2047Open in exhaust fuel addition injector circuit
P2238Open or short in A/F sensor or heater circuit (Low output)
P2239Open or short in A/F sensor or heater circuit (High output)

A91221
Common Rail System Diagram (1CD−FTV Fuel System):
Sensors ECM EDU
Common Rail
Fuel Pressure SensorPressure Discharge
Valve
Supply Pump Assy
Suction Control Valve
Fuel TankMain
Injector
Fuel Filter
: High−pressurized Area
Exhaust Fuel
Addition Injector
Exhaust Port
To DPNR
Catalytic
Converter 05−260
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
3. COMMON RAIL SYSTEM DESCRIPTION
(a)COMMON RAIL SYSTEM:
The common rail system stores high−pressurized fuel supplied from the supply pump in the common rail and
injects it using the injectors. 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−pressurized 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−Wa y
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 to180 MPa (306 to
1,835 kgf/cm
2, 4,351to 26,106 psi). The ECM opens and closes the pressure discharge valve to improve
controllability for the common rail internal fuel pressure.
This system has two split fuel injections. It performs ”pilot−injection” as subsidiary fuel injection prior to the
main fuel injection to make combustion soft, and this helps to reduce engine vibration and noise.