Page 649 of 5135
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±525
AVENSIS REPAIR MANUAL (RM1018E)
16CHECK FOR INTERMITTENT PROBLEMS (See page 05±528)
GO TO STEP 18
17 PARTS INSPECTION
18 IDENTIFICATION OF PROBLEM
19 ADJUSTMENT, REPAIR
20 CONFIRMATION TEST
END
Page 650 of 5135
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.
Page 651 of 5135
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
Page 652 of 5135
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.
Page 653 of 5135
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.
Page 654 of 5135
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.
Page 655 of 5135
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
(
)
( )
(
)
( )
(
)( )( )
(
)
( )
( )
(
)
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
Page 656 of 5135
±
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