Page 4329 of 5135

054JC−11
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Date Vehicle
Brought in
VIN
Production Date
Licence Plate No.
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Driveability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after−fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Data Problem
Occurred
Problem Frequency
Condition When
Problem Occurs
Weather
Engine Operation
Engine Temp. Place Outdoor
TemperatureConstant
Sometimes ( times per day/month)Once only
Other
Fine
CloudyRainySnowyVarious/Other
Hot
Warm Cool
HighwaySuburbsInner CityUphillDownhill
Rough road
Other
Cold
Warming upAfter Warming upAny temp.Other
Starting
Just after starting ( min.)IdlingRacing
Driving
Constant speedAccelerationDeceleration
A/C switch ON/OFF
Other
Condition of malfunction indicator lamp
(CHK ENG)Remains on Sometimes lights up Does not light up
Normal Malfunction code(s) (code )
Freeze frame data ( )
Normal Malfunction code(s) (code )
Freeze frame data ( )
Normal mode
(Pre−check)
Check Mode DTC InspectionInspector’s
Name
Cold (approx._C/_F)
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−269
AVENSIS Supplement (RM1045E)
CUSTOMER PROBLEM ANALYSIS CHECK
Page 4330 of 5135
054JB−11
05−266
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
HOW TO PROCEED WITH TROUBLESHOOTING
The hand −held tester can be used at step 3, 4, 5, 7, 10.
1 VEHICLE BROUGHT TO WORKSHOP
2 CUSTOMER PROBLEM ANALYSIS (See page 05 −269)
3 CONNECT THE HAND −HELD TESTER TO DLC3
HINT:
If the display indicates a communication fault in the tool, inspect DLC3.
4 CHECK DTC AND FREEZED FRAME DATA (See page 05 −299)
HINT:
Record or print DTCs and Freezed Frame Data, if needed.
5 CLEAR DTC AND FREEZED FRAME DATA (See page 05 −290)
6 VISUAL INSPECTION
7 SET CHECK (TEST) MODE DIAGNOSIS (See page 05 −29 1)
8 PROBLEM SYMPTOM CONFIRMATION
HINT:
If the engine does not start, perform step 10 and 12 first.
AMalfunction does not occur
BMalfunction occurs
B GO TO STEP 10
A
Page 4331 of 5135
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −267
AVENSIS Supplement (RM 1045E)
9 SYMPTOM SIMULATION (See page 05 −282)
1 0 DTC CHECK (See page 05 −290)
AMalfunction code
BNo code
B GO TO STEP 12
A
11 PROCEED TO DTC CHART (See page 05 −299)
GO TO STEP 14
12 BASIC INSPECTION (See page 05 −27 1)
ANot confirm wrong parts
BConfirm wrong parts
B GO TO STEP 17
A
1 3 PROCEED TO PROBLEM SYMPTOMS TABLE (See page 05 −282)
AConfirm wrong circuit
BConfirm wrong Parts
B GO TO STEP 17
A
1 4 CHECK ECM POWER SOURCE CIRCUIT (See page 05 −489)
1 5 CIRCUIT INSPECTION
ANot confirm malfunction
BConfirm malfunction
B GO TO STEP 18
A
Page 4332 of 5135
05−268
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
16 CHECK FOR INTERMITTENT PROBLEMS (See page 05 −270)
GO TO STEP 18
17 PARTS INSPECTION
1 8 PROBLEM IDENTIFICATION
1 9 ADJUSTMENT AND/OR REPAIR
20 CONFIRMATION TEST
END
Page 4333 of 5135

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
Page 4334 of 5135

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.
Page 4335 of 5135

− 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.
Page 4336 of 5135

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