TOYOTA AVENSIS 2005 Service Repair Manual

− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−393
AVENSIS Supplement (RM1045E)
DTC P0400 EXHAUST GAS RECIRCULATION FLOW
CIRCUIT DESCRIPTION
The EGR system recirculates exhaust gases, and which is controlled to the proper volume to be suited every
driving condition. The recirculated gas mingles with the intake air, therefore the EGR system can slow down
engine combustion and let the combustion temperature down. This helps reduce a NOx emission.
In order to increase a circulatory efficiency, the ECM adjusts the lift amount of the EGR valve and intake
shutter valve (throttle valve).
DTC No.DTC Detection ConditionTrouble Area
P0400Target and actual positions of the EGR valve is different
(1trip detection logic)
SEGR valve stuck
SEGR valve does not move smoothly
SOpen or short in EGR circuit
SOpen or short in EGR valve position sensor circuit
SEGR valve position sensor
SECM
05I7N−01

A93020
Malfunction Detection:
Abnormal
(Does not move smoothly) EGR Valve Opening
Position (Target)
Normal
Open
EGR Valve Position Sensor
Opening Position (Actual)Close
Abnormal
(Stuck)
Time
Threshold
Malfunction CounterDetect P0400Open
Close 05−394
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
MONITOR DESCRIPTION
When the target and actual positions of the EGR valve is different, the ECM interprets this as malfunction
of the EGR valve and illuminates the CHK ENG.

A91220
MREL B−W
GR8
3 EFI MAIN Relay
W−BE9 E12
2 IE1
EE1
EFIB−R
(LHD) 1
B5
Battery FL MAINE17
EGR Valve
EGRS 3
1
1
1
1A 1 1
121 2R−L
B−W 10GR
Engine Room R/B No.1ECM
2
1
Engine Room
R/B No. 3 3
3 B
EC B−Y
(RHD)
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−395
AVENSIS Supplement (RM1045E)
WIRING DIAGRAM
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.
SAfter engine warm−up, DTC P0400 malfunction is set1second or more passed after quickly accelerat-
ing the engine from idling.
1CHECK OTHER DTC OUTPUT(IN ADDITION TO P0400)
(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
P0400A
P0400 and P0405 and/or P0406B
HINT:
If any other codes besides P0400 are output, perform troubleshooting for those DTCs first.

A93008
EGR Valve
Component Side:
E17
1
2
05 −396
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
B GO TO RELEVANT DTC CHART
(See page 05 −299)
A
2 READ VALUE OF HAND −HELD TESTER(EGR VALVE POS)
(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 EGR VALVE POS” and read its value displayed on the hand −held tester.
Result:
ConditionResultProceed to
After engine warm −up, quickly accelerateConstant or changes slowlyAAfter engine warm up, quickly accelerate
the engine from idling to 3,000 rpm by us-
ing accelerator pedalSmooth changes from approximately 3.0 V to
approximately 2.0 VB
HINT:
EGR valve closed: EGR VALVE POS is 4.0 V
EGR valve open: EGR VALVE POS is 2. 1 V
B CHECK FOR INTERMITTENT PROBLEMS (See page 05 −270)
A
3 INSPECT EGR VALVE ASSY(RESISTANCE)
(a) Disconnect the E 17 EGR valve connector.
(b) M easur e t he r esist ance bet ween t he t er m inals of t he
EGR valve.
Standard:
Tester ConnectionSpecified Condition
1−2approximately 7.0
at 20 _ C (68 _ F)
(c) Reconnect the EGR valve connector.
NG REPLACE EGR VALVE ASSY (See page 14−1 08)
OK

A85349
E17
Wire Harness Side:
EGR Valve Connector
Front View
A81087
E12
ECM ConnectorEGRS
A66056
Engine Room R/B No.1:
EFI MAIN Relay
A85349
E17
Wire Harness Side:
EGR Valve Connector
Front View
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−397
AVENSIS Supplement (RM1045E)
4 CHECK HARNESS AND CONNECTOR(EGR VALVE ASSY−ECM)
(a) Disconnect the E17 EGR valve connector.
(b) Disconnect the E12 ECM connector.
(c) Check the resistance between the wire harness side con-
nectors.
Standard (Check for open):
Tester ConnectionSpecified Condition
EGRS (E12−3)−EGR valve (E17−1)Below1
E2 (E13−28)−(E17−2)Below1

Standard (Check for short):
Tester ConnectionSpecified Condition
EGRS (E12−3) or EGR valve (E17−1)−Body ground10k
or higher
(d) Reconnect the EGR valve connector.
(e) Reconnect the ECM connector.
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
5 CHECK HARNESS AND CONNECTOR(EGR VALVE−EFI MAIN RELAY)
(a) Remove the EFI MAIN relay from the engine room R/B
No.1.
(b) Disconnect the E17 EGR valve connector.
(c) Check the resistance between the wire harness side con-
nectors.
Standard (Check for open):
Tester ConnectionSpecified Condition
EFI MAIN relay (1)−EGR valve (E17−2)Below1

Standard (Check for short):
Tester ConnectionSpecified Condition
EFI MAIN relay (1) or EGR valve (E17−8)−Body ground10k
or higher
(d) Reinstall the EFI MAIN relay.
(e) Reconnect the EGR valve connector.
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK

A66060
E12
ECM Connector EGRS
E 1
A9 1226
Signal Waveform
5V/
Division
GND
5 msec./Division
EGRS
05
−398
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
6 INSPECT ECM(EGR VALVE ASSY VOLTAGE)
(a) Inspect using the oscilloscope.
(b) During idling, check the waveform between the specified
terminals of the E 12 ECM connector.
Standard:
Tester ConnectionSpecified Condition
EGRS (E 12− 3) − E1 (E 12− 7)Correct waveform is as shown
NG REPLACE ECM (See page 10− 29)
OK
REPLACE EGR VALVE ASSY (See page 14−1 08)

A81017
Generator (Alternator)Glow Plug ECMGlow
Plug
Relay Battery
Duty Ratio
A81018
Ignition Switch
Glow Plug
Engine Speed
Starting EngineAfter Glow Time OFFOFF ON ON
OFF After Glow System:
0
020
(68)40
(104)
After Glow Time (second)Engine Coolant Temperature_C(_F) 120 05−386
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
DTC P0380 GLOW PLUG/HEATER CIRCUIT ”A”
CIRCUIT DESCRIPTION
The glow plug is mounted inside the engine combustion chamber. To ensure the efficient engine starting with
a cold engine, the ECM calculates a time interval of the current needs to flow through the glow plug depend-
ing on the starting engine coolant temperature when the ignition switch is turned to ON. The ECM then turns
on the glow plug relay and permits the current to flow through the glow plug based on the ECM’s calculated
time. The glow plug is then heated and enhances fuel combustion with a cold engine.
This DTC will be set if there is open in glow plug itself or its circuit.
HINT:
After the engine is started, the ECM performs an ”after−glow” for a certain period of time. In proportion to
the actual engine coolant temperature, the time period varies. The after−grow reduces diesel engine knock-
ing, white smoke and engine noises with a cold engine.
05CPT−03

− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−387
AVENSIS Supplement (RM1045E)DTC No.
DTC Detection ConditionTrouble Area
P0380
When the glow plug is turned from ON to OFF, or vice versa,
conditions (a) and (b) are satisfied:
(2 trip detection logic)
(a) Battery voltage does not change
(b) Duty signal from terminal M of the generator (alternator)
does not changeSOpen or short in glow plug circuit
SGlow fuse
SGlow plug relay
SGlow plug
SECM
MONITOR DESCRIPTION
When starting a cold engine, the ECM supplies current to the glow plug for a certain period of time. As supply-
ing the current to the glow plug is terminated, the large current is suddenly cut off, therefore the battery volt-
age then varies and also the output (duty ratio) from terminal M of the generator (alternator) varies. If these
variations are not occurred when the glow plug is turned from ON to OFF, or vice versa, the ECM judges the
current has not been supplied to the glow plug, and interprets this as open malfunction of the glow plug or
glow plug circuit.
MONITOR STRATEGY
Required SensorsGlow plug circuit
Frequency of operationTwice per driving cycle
Duration3 minutes
CHK ENG Operation2 driving cycles
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
Battery voltage11 V−
Engine speed700 rpm2,000 rpm
Engine coolant temperature−40_C (104_F)
Engine speed is stable−
Time after engine start8 seconds−
Any switches that vary electrical load
have not been being operated−
The monitor will not run if the generator (alternator) circuit is malfunctioning
TYPICAL MALFUNCTION THRESHOLDS
Threshold
When the battery voltage, or output (duty ratio) from terminal M of the generator (alternator) does not change, despite the ECM turning the glow
plug from ON to OFF, or vice versa

A81005
ECM
ALT 8
E13
IK1 G−Y
G2
GLOW
Relay1
2 3
G1
Glow Plug110
GLOW
Battery
EI R
4 B−L
B
FL
MAIN
BR B
ALT
12
12
33
BB
Engine Room
R/B No. 3
IJBR BR
B
B 3
333
1 25 15DH
DN 1 DH
18DB 9 DA ECU−IG I13
Ignition Switch 3
1
AM1AM1 IG1
G−R
ED1 1
WDriver
Side J/B
IG1
RelayA12 1
BB−L
A11 3
MY
A11 4
LRL 9
E13
Generator
(Alternator)
IG S
2A11
1 A11 A11
R−WB
IK21
EE1 5GREL 15
E9
R
R
B
R−W R−W
W−B
G J10(LHD)
C J20(RHD)
J/C
G J10(LHD)
C J20(RHD)
ALT−SEFI
1 2
1 2 11
11AEngine
Room
R/B No. 1 IE3 7 (LHD)
(RHD)
IO1 7BATT 2
E10
E1 7
E12 B−Y
B
B−R (LHD)
B−Y (RHD)
05−388
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
WIRING DIAGRAM

A81506
From Battery
Glow System Wiring Diagram:
Glow Plug Relay
Glow Plug ECM
GREL
GLOW Fuse
−
DIAGNOSTICS ECD SYSTEM (1CD−FTV)(From September, 2003)
05 −389
AVENSIS Supplement (RM1045E)
INSPECTION PROCEDURE
HINT:
S After completing repairs, confirm that P0380 is not present again.
S 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 OTHER DTC OUTPUT(IN ADDITION TO DTC P0380)
(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
P0380A
P0380 and P0622B
HINT:
If any other codes besides P0380 and P0622 are output, perform troubleshooting for those DTCs first.
B GO TO RELEVANT DTC CHART(See page 05 −299)
A