TOYOTA AVENSIS 2005 Service Repair Manual

A80985
A66061
A66062
A66068
A66069
05±540
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Enter ºDIAGNOSIS / OBD/MOBD / DIAGNOSTIC MENU
ECDº and select the item ºINJECTOR COMP.º
(e) Press the ºENTERº button on the hand±held tester.
(f) Press the ºEnterº button again.
(g) Select ºSET COMP VALUEº and press the ºENTERº but-
ton.
(h) Press the ºENTERº button.
(i) Select a cylinder number which you want to register the
compensation code.
(j) Press the ºENTERº button.

A66070
A66071
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A66073
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±541
AVENSIS REPAIR MANUAL (RM1018E)
(k) Input the 30±digit±alphanumeric code with the hand±
held tester to register the compensation code to the ECM.
NOTICE:
Be careful not to register a wrong compensation code to
the ECM. The compensation code which stored in the ECM
must be consistent with the compensation code of the in-
jector assembly. If a wrong code was set to the ECM, rough
idling or engine rattling may result. In addition, it may be a
cause of the engine failure or short±life.
(l) After inputting, press the ºENTERº button.
(m) Press the ºENTERº button again.
(n) Confirm the injection compensation code which is dis-
played on the hand±held tester.
HINT:
The code shown in the illustration is an example.
NOTICE:

Make sure the correct compensation code is entered
on the hand±held tester before pressing YES button.

If a wrong compensation code was entered on the
hand±held tester, select the ºNOº button to correct
the error (Back to step (g)).
(o) Press the ºYESº button to set the code to the ECM.
(p) Wait until the next screen comes up.

A66074
A66289
Inside
05±542
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(q)Press the ºNOº button to complete the registration.
HINT:

If you want to register other compensation code for other
cylinders, press the ºYESº button instead of ºNO.º

By pressing the ºNOº button, the hand±held tester returns
to the ºDIAGNOSTIC MENU ECDº screen.
BASIC INSPECTION
When the malfunction is not confirmed in the DTC check, troubleshooting shou\
ld be carried out in all the
possible circuits considered as causes of the problem. In many cases, by carrying out the basic engine check
shown in the following flow chart, the location causing the problem can be found quickly and efficiently.
Therefore, using this check is essential in the engine troubleshooting.
1CHECK BATTERY VOLTAGE
NOTICE:
Carry out this check with the engine stopped and ignition switch OFF.
OKNG
Voltage11 V or moreLess than 11 V
NGCHARGE OR REPLACE BATTERY
OK
2CHECK IF ENGINE WILL CRANK
NGPROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05±551
OK
3 CHECK AIR FILTER
(a) Visually check that the air filter is not excessively dirty or oily.
NOTICE:
If necessary, clean the filter with compressed air. First blow
from the inside thoroughly, then blow from the outside of
the filter.
NG CLEAN OR REPLACE
OK

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±543
AVENSIS REPAIR MANUAL (RM1018E)
4CHECK FUEL QUALITY
(a)Check that only diesel fuel is used
(b)Check that the fuel does not contain any impurity.
NGREPLACE FUEL
OK
5CHECK ENGINE OIL (See page 17±20)
NGADD OR REPLACE
OK
6CHECK ENGINE COOLANT (See page 16±37)
NGREPLACE ENGINE COOLANT (See page 16±44)
OK
7CHECK IDLE SPEED AND MAXIMUM SPEED (See page 14±266)
NGREPAIR OR REPLACE INJECTION PUMP (See page 11±69)
OK
8CHECK DIAGNOSTIC CIRCUIT
NGREPAIR OR REPLACE
OK
9CHECK VACUUM PUMP
NGREPAIR OR REPLACE VACUUM PUMP
OK
PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE (See page 05±551)

054JC±04
ENGINE CONTROL SYSTEM Check Sheet
Customer's Name
Driver's Name
Date Vehicle
Brought in
License No.
VIN
Production Date
Licence 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 check engine warning light
(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)
05±527
AVENSIS REPAIR MANUAL (RM1018E)
CUSTOMER PROBLEM ANALYSIS CHECK

05CPA±01
05±526
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
PRECAUTION
1. Since each injector has a characteristic fuel injecting behavior, the ECM compensates such be-
havior by adjusting an injection time for each injector to optimize the fuel injection volume.
Compensating data for the optimum injection volume, which has converted into a 30±digit±al-
phanumeric value, has been imprinted on a head potion of the injector as the injection com-
pensation code.
2. The injection compensation code will be required to register to the ECM when replacing the in-
jectors or the ECM.
3. If an incorrect injection compensation value was registered to the ECM, the engine assembly
may rattle or the engine idling may be rough. In addition, it may be a cause of the engine failure
or short±life.

054JB±04
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±523
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO PROCEED WITH TROUBLESHOOTING
1VEHICLE BROUGHT TO WORKSHOP
2CUSTOMER PROBLEM ANALYSIS (See page 05±527)
3CONNECT THE HAND±HELD TESTER TO DLC3
HINT:
If the display indicates a communication fault in the tool, inspect DLC3.
4CHECK DTC AND FREEZE FRAME DATA(See page 05±528)
HINT:
Record or print DTC and freeze frame data, if needed.
5CLEAR DTC AND FREEZE FRAME DATA (See page 05±528)
6 VISUAL INSPECTION
7SETTING THE CHECK (TEST) MODE DIAGNOSIS (See page 05±528)
8 PROBLEM SYMPTOM CONFIRMATION
HINT:
If the engine does not start, perform steps 10 and 12 first.
AMalfunction does not occur
BMalfunction occurs
B GO TO STEP 10
A

05±524
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
9SYMPTOM SIMULATION
10DTC CHECK (See page 05±528)
AMalfunction code
BNo code
BGO TO STEP 12
A
11DTC CHART (See page 05±544)
GO TO STEP 14
12BASIC INSPECTION (See page 05±528)
AWrong parts not confirmed
BWrong parts confirmed
BGO TO STEP 17
A
13PROBLEM SYMPTOMS TABLE (See page 05±551)
AWrong circuit confirmed
BWrong parts confirmed
B GO TO STEP 17
A
14CHECK ECM POWER SOURCE CIRCUIT (See page 05±686)
15 CIRCUIT INSPECTION
AMalfunction not confirmed
BMalfunction confirmed
B GO TO STEP 18
A

±
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

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.