TOYOTA AVENSIS 2005 Service Repair Manual

A84847
EP1 EP2VPA2
VCP 1
VPA1VCP2
A20
Wire Harness Side (RHD):
Front View
Accelerator Pedal Position Sensor
Connector
A84847
EP
1
EP2VPA2
VCP1
VPA 1
VCP2
A20
Accelerator Pedal Position Sensor
Connector
Wire Harness Side (LHD):
Front View
A8109 1
E9
ECM Connector VPA
VCPA
VPA2
EPA2 VCP2EPA
05−478
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
5 CHECK HARNESS AND CONNECTOR(ACCELERATOR PEDAL POSITION
SENSOR − ECM)
(a) Disconnect the A20 accelerator pedal position sensor
connector.
(b) Disconnect the E9 ECM connector.
(c) Check the resistance between the wire harness side con- nectors.
Standard (Check for open) (RHD):
Tester ConnectionSpecified Condition
VPA1 (A20 −5) − VPA (E9 −22)
EP 1 (A20 −1 )− EPA (E9 −28)
VCP 1 (A20 −4) − VCPA (E9 −26)Below1
VPA2 (A20 −2) − VPA2 (E9 −23)Below 1

EP2 (A20 −3) − EPA2 (E9 −29)
VCP2 (A20 −6) − VCP2 (E9 −27)
Standard (Check for open) (LHD):
Tester ConnectionSpecified Condition
VPA 1 (A20 −5) − VPA (E9 −22)
EP 1 (A20 −3) − EPA (E9 −28)
VCP 1 (A20 −6) − VCPA (E9 −26)Below1
VPA2 (A20 −2) − VPA2 (E9 −23)Below 1

EP2 (A20 −1 )− EPA2 (E9 −29)
VCP2 (A20 −4) − VCP2 (E9 −27)
Standard (Check for short) (RHD):
Tester ConnectionSpecified Condition
VPA 1 (A20 −5) or VPA (E9 −22) − Body ground
EP 1 (A20 −1 ) or EPA (E9 −28) − Body ground
VCP 1 (A20 −4) or VCPA (E9 −26) − Body ground10 k
or higherVPA2 (A20 −2) or VPA2 (E9 −23) − Body ground10k
or higher
EP2 (A20 −3) or EPA2 (E9 −29) − Body ground
VCP2 (A20 −6) or VCP2 (E9 −27) − Body ground
Standard (Check for short) (LHD):
Tester ConnectionSpecified Condition
VPA 1 (A20 −5) or VPA (E9 −22) − Body ground
EP 1 (A20 −3) or EPA (E9 −28) − Body ground
VCP 1 (A20 −6) or VCPA (E9 −26) − Body ground10 k
or higherVPA2 (A20 −2) or VPA2 (E9 −23) − Body ground10k
or higher
EP2 (A20 −1 ) or EPA2 (E9 −29) − Body ground
VCP2 (A20 −4) or VCP2 (E9 −27) − Body ground
(d) Reconnect the accelerator pedal position sensor connec-
tor.
(e) Reconnect the ECM connector.
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
REPLACE ECM (See page 10− 29)

A85357
DPNR (Diesel Particulate−NOx Reduction System) Catalyst Monolithic Construction:
NO, PM
HC, CO N2, CO2
H
2O
Exhaust Gas Temperature
Sensor (on up stream) ECM
Exhaust Gas Temperature
Sensor (on down stream)
Wall −Flow Type:
Differential Pressure Sensor
Cross Section
Magnified ViewGas Flow
PM
Exhaust Gas
DPNR (Diesel Particulate −NOx Reduction System):
DPNR Catalytic
Converter
05
−466
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
DTC P2002 PARTICULATE TRAP EFFICIENCY BELOW
THRESHOLD (BANK 1)
HINT:
S For more information on the DPNR (* 1) catalytic converter and TOYOTA D −CAT (*2), see page
05 −255.
S If P2002 is present, refer to the diagnostic trouble codes (DTCs) table for TOYOTA D −CAT on page
05 −255.
* 1 : Diesel Particulate −NOx Reduction system.
*2: Diesel Clean Advanced Technology.
CIRCUIT DESCRIPTION
DPNR catalyst has ability to reduce nitrogen oxides (NOx) and particulate matter (PM) in addition to purifica-
tion of hydrocarbons (HC) and carbon monoxides (CO). DPNR material is monolithic construction. Its inlets
and outlets block up with each other, and its surface is coated with NOx absorptive deduction −type catalyst.
Because exhaust gases flow through micro −cavities inside walls, it is called ”wall −flow” type.
05I83 −01

A91205
Malfunction Detection:
DPNR Catalyst Regeneration
(Activation of Fuel Addition)
Approximately 300_C (572_F) OFFON
NormalMore than
Approximately 600_C(1,112_F)
Abnormal
Time Exhaust Gas Temperature
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−467
AVENSIS Supplement (RM1045E) DTC No.
DTC Detection ConditionTrouble Area
P2002
Condition (a) or (b) is met (1trip detection logic):
(a) Differential pressure exceeds a standard level for more than
10 seconds
(b) Exhaust gas temperature does not raise during DPNR cata-
lyst regeneration
SDPNR catalytic converter (Manifold converter sub−assy)
SDifferential pressure sensor
SDifferential pressure sensor vacuum hose is clogged
SBlockage in Vacuum transmitting pipe sub−assy
SExhaust gas temperature sensor
SExhaust gas leaks in TOYOTA D−CAT
SMass air flow meter
SECM
MONITOR DESCRIPTION
In order to detect abnormality in the DPNR (*3) catalytic converter, the ECM monitors an exhaust gas temper-
ature as well as a differential pressure of the exhaust gas. For monitoring the differential pressure, the ECM
compares the up−and downstream pressure of the DPNR catalytic converter. If the difference between the
pressure is large, the ECM judges that the DPNR has contaminated or deteriorated, and then illuminates
the CHK ENG.
Furthermore, the ECM monitors increase in the exhaust gas temperature while the exhaust fuel addition in-
jector adds fuel under DPNR catalyst regeneration. The exhaust gas temperature during the DPNR catalyst
regeneration normally rises from approximately 300_C (572_F) to approximately 600_C(1,112_F) or higher.
If the temperature does not rise even if a certain period of time has elapsed, the ECM interprets this as mal-
function of the DPNR and illuminates the CHK ENG.
*3: Diesel Particulate−NOx Reduction system.
INSPECTION PROCEDURE
HINT:
SRead freeze frame data usingthe hand−held tester.Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the
vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or
rich, and other data from the time the malfunction occurred.
SIf (exhaust gas) differential pressure (DPNR DIFF PRESS) of the DPNR catalytic converter does not
virtually develop when increasing the engine speed, the DPNR catalytic converter may be malfunction-
ing.

05−468
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
1 CHECK OTHER DTC OUTPUT(IN ADDITION TO P2002)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES”.
(d) Read DTCs.
Result:
Display (DTC output)Proceed to
P2002A
P2002 and other DTCsB
HINT:
If any other codes besides P2002 are output, perform troubleshooting for those DTCs first.
B GO TO RELEVANT DTC CHART(See page 05 −299)
A
2 READ VALUE OF HAND −HELD TESTER(DIFFERENTIAL PRESSURE)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Start the engine.
(d) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / DPNR DIFF PRESS”.
(e) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / MAF”.
(f) Check that differential pressure. Result:
Engine Speed (Vehicle is stop)Differential Pressure (kPa)Proceed to
3,000 rpm (No engine load)Less than MAF rate (mass air flow rate)
0.4A
3,000 rpm (No engine load)More than MAF rate (mass air flow rate)
0.4B
HINT:
SIf the differential pressure is more than a value that the intake air amount (MAF: g/sec) is multiplied
by 0.4, DTC P2002 (Particulate Trap Efficiency Below Threshold [Bank 1]) will be present.
SThe standards for the differential pressure sensor are as follows.
Reference:
Engine ConditionDifferential Pressure OutputSensor Condition
Ignition Switch ONApproximately 0 kPaNormal
Always3 kPaOpen or short circuit
3,000 rpm (No engine load)Negative outputIncorrect arrangement of hose piping
B Go to step 4
A

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −469
AVENSIS Supplement (RM 1045E)
3 READ VALUE OF HAND −HELD TESTER(EXHAUST GAS TEMPERETURE)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Start the engine.
(d) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / EX TEMP (IN) and EX TEMP (OUT)”.
(e) Check that exhaust gas temperature is within the specification below. Reference:
ConditionExhaust Gas Temperature ( _ C)
Idling after engine warm −upConstant at approximately 50 to 700 ( 122 to 1,292 _ F) *3
*3: There should be no noise.
NG REPAIR OR REPLACE EXHAUST GASTEMPERATURE SENSOR, HARNESS OR
CONNECTOR
OK
4 CHECK BLOCKAGE(DIFFRENTIAL PRESSURE SENSOR)
CAUTION:
Be careful for being burned by exhaust gases during the following inspection.
(a) Disconnect the vacuum hose (both up −and downstream) on the differential pressure sensor side.
(b) Start the engine.
(c) Check if there is exhaust gas pulsations from both vacuum hoses during idling.
NG REPLACE CLOGGED PARTS(See page 14−1 08)
OK
5 CHECK FOR EXHAUST GAS LEAKS
(a) Check that there is no exhaust gas leak in the exhaust system components and differential pressure sensor vacuum hoses.
NG REPAIR OR REPLACE LEAKAGE POINT
OK
REPLACE MANIFOLD CONVERTER SUB −ASSY (See page 14−1 08)

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −465
AVENSIS Supplement (RM 1045E)
DTC P 160 1 INJECTOR CORRECTION CIRCUIT
MALFUNCTION (EEPROM)
NOTICE:
S If an incorrect injector compensation code was registered with the ECM, it may rattle the engine
assembly or the engine idling may become rough. In addition, it may become a cause of engine
failure or shorten the life of the engine.
1 . If you replace the ECM with a new one, register all the injector compensation codes with the
new ECM as follows:
(a) Prior to replacing the ECM, read all the compensation codes stored in the existing ECM using the hand−held tester, and then write them down (see page 05 −273).
(b) After replacing the ECM, enter the written compensation codes into the ECM using the hand −held tes-
ter (see page 05 −277).
(c) Turn the ignition switch to OFF and wait for 30 seconds or more.
(d) Turn the ignition switch to ON, then clear DTC P 160 1 using the hand −held tester (see page 05 −290).
HINT:
S In order to optimize the injector ’s fuel injection characteristic, the ECM compensates the injection dura-
tion by each cylinder. The ECM stores and uses compensating data in the form of a 30 −digit −alphanu-
meric value that is imprinted on the head portion of each injector as the injector compensation code.
S If you installed a new injector, its own injector compensation code is needed to register with the ECM.
Also, if you replaced the ECM, the compensation codes of all the injectors are needed to register be-
cause the new ECM dose not have the codes until they are registered.
S Once the ECM is replaced, DTC P 160 1 will be present when turning the ignition switch to ON. This
is to inform you that the injector compensation codes are required to register with the ECM. In order
to clear the DTC, register the compensation codes first, then turn the ignition switch to OFF and wait
for 30 seconds or more.
CIRCUIT DESCRIPTION
DTC No.DTC Detection ConditionTrouble Area
P 160 1
Injector compensation code is not registered
(1 trip detection logic)
S Injector compensation codeP 160 1Wrong injector compensation code is registered
(1 trip detection logic)
Injector compensation code
S ECM
INSPECTION PROCEDURE
HINT:
Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was
running or stopped, if the engine was warmed up or not, if the air −fuel ratio was lean or rich, and other data
from the time the malfunction occurred.
1 CHECK INJECTOR COMPENSATION CODE (See page 05 −273)
NG SET INJECTOR COMPENSATION CODE
(See page 05 −277)
OK
REPLACE ECM (See page 10− 29)
05CQ2 −03

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −457
AVENSIS Supplement (RM 1045E)
DTC P 1425 DIFFERENTIAL PRESSURE SENSOR
CIRCUIT
DTC P 1427 DIFFERENTIAL PRESSURE SENSOR
CIRCUIT LOW
DTC P 1428 DIFFERENTIAL PRESSURE SENSOR
CIRCUIT HIGH
HINT:
S For more information on the differential pressure sensor and TOYOTA D −CAT (* 1), see page 05 −255.
S If P 1425, P 1427 and/or P 1428 is present, refer to the diagnostic trouble codes (DTCs) table for TOYO-
TA D −CAT on page 05 −255.
* 1 : Diesel Clean Advanced Technology.
05I82 −01

A85356
ECM
Exhaust Gas
Exhaust Gas Differential Pressure (kPa)
Differential Pressure Voltage (V)
1.530
0.750
0.530
0
−5.020.0100.0 Detect P1425 or P1428
5.000
4.700 4.800
0 0.400
Differential Pressure
Sensor
Property of Output Voltage:
Detect P1425 or P1427
DPNR Catalytic
Converter 05−458
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
CIRCUIT DESCRIPTION
Two sensible portions of the differential pressure sensor are mounted before and after the DPNR (*2) catalyt-
ic converter and monitor exhaust gas differential pressure. The sensor itself is located far from the engine
assembly to reduce the influence of vibration, and is a semiconductor−type that is not influenced by exhaust
gases.
The ECM compares the exhaust gas pressure before and after DPNR catalytic converter by monitoring the
pressure using the up−and downstream sensible portions of the differential pressure sensor. If difference
between the pressure before and after the catalytic converter exceeds a standard level, the ECM judges
that the catalytic converter has clogged with particulate matter (PM). When once the ECM judges it, the ECM
begins to exercise the DPNR catalyst regeneration.
When output voltage of the sensor deviates from the normal operating range, the ECM interprets this as
malfunction of the sensor circuit, and sets DTC P1425, P1427, or P1428 and then illuminates the CHK ENG.
*2: Diesel Particulate−NOx Reduction system.
HINT:
If vacuum hoses of the differential pressure sensor for up−and downstream sensible portions are connected
to a upside down, the ECM interprets this as abnormal pressure difference, therefore DTC P1426 (Differen-
tial Pressure Sensor [Installation]) will be set and the CHK ENG will illuminate.

A91215
VCECM
PEX
E2 W R−W
BR D22
Differential Pressure Sensor
13
218
E13
20
E12
28
E13 VC
GNDVPR−W
W
BR EE1
EE1
EE1 4
9 8
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−459
AVENSIS Supplement (RM1045E) DTC No.
DTC Detection ConditionTrouble Area
P1425
Differential pressure sensor output voltage is less than
0.4 V, or more than 4.8 V for 3 seconds or more
(1trip detection logic)
SOpen or short in differentialpressure sensor circuit
P1427
Differential pressure sensor output voltage is less than
0.4 V for 3 seconds or more
(1trip detection logic)
SOpenorshortindifferentialpressuresensorcircuit
SIncorrect arrangement differential pressure sensor hose pip-
ing
SDifferential pressure sensor
P1428
Differential pressure sensor output voltage is more than
4.8 V for 3 seconds or more
(1trip detection logic)
ee tap essu ese so
SECM
HINT:
SDTC P1426 (Differential pressure sensor [installation]) will be present if there is incorrect vacuum hose
arrangement of the differential pressure sensor.
SAfter confirming DTC P1425, P1427 and P1428, check the differential pressure in the ”DIAGNOSIS
/ OBD/MOBD / DATA LIST / ALL / DPNR DIFF PRESS ” using the hand−held tester.
Reference:
Engine ConditionDifferential Pressure OutputSensor Condition
Ignition Switch ONApproximately 0 kPaNormal
Always3 kPaOpen or short circuit
3,000 rpm (No engine load)Negative outputIncorrect arrangement of hose piping
MONITOR DESCRIPTION
In order to detect abnormality in the differential pressure sensor at any time, the ECM always monitors output
voltage from the sensor. When the sensor output voltage deviates from the normal operating range (between
0.4 V and 4.8 V) for more than 3 seconds, the ECM interprets this as malfunction of the sensor circuit and
illuminates the CHK ENG.
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
Read freeze frame data usingthe hand−held tester.Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was
running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, and other data
from the time the malfunction occurred.

05−460
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
1 READ VALUE OF HAND −HELD TESTER(DIFFERENTIAL PRESSURE)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / DPNR DIFF PRESS”.
(d) Check that differential pressure is within the specification below.
Result:
ConditionDifferential PressureProceed to
Always−5 kPa or lessA
Ignition Switch ON−4 kPa to 98 kPaB
Always99 kPaC
B CHECK FOR INTERMITTENT PROBLEMS
(See page 05 −270)
C Go to step 3
A
2 CHECK CONNECTION OF VACUUM HOSE(DIFFERENTIAL PRESSURE SENSOR −
VACUUM TRANSMITTING PIPE)
(a) Check if vacuum hose arrangement between the differential pressure sensor and the vacuum trans-
mitting pipe is not incorrect arrangement (see page 14−1 08).
(b) Check that there is no exhaust gas leak between the differential pressure sensor and the vacuum transmitting pipe (see page 14−1 08).
NG CORRECT TO NORMAL CONNECTION
OK
3 CHECK BLOCKAGE(DIFFERENTIAL PRESSURE SENSOR)
CAUTION:
Be careful for being burned by exhaust gases during the following inspection.
(a) Disconnect the vacuum hose (both up −and downstream) on the differential pressure sensor side.
(b) Start the engine.
(c) Check if there is exhaust gas pulsations from both vacuum hoses during idling.
NG REPLACE CLOGGED PARTS(See page 14−1 08)
OK