TOYOTA AVENSIS 2005 Service Repair Manual

A81906
ECM
D1
Intake Shutter
B
LU+A 15
E13
G
Y
LE13
E13
E1314
13
12LU±A
LU+B
LU±B 6
4
3
1From EFI MAIN Relay
5
2B±W
B±W
B±W
P±L
E1311
THOP 1
2 W±B
EIT3
Intake Shutter
Fully Opened Switch
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±635
AVENSIS REPAIR MANUAL (RM1018E)
TYPICAL MALFUNCTION THRESHOLDS
Threshold
Intake shutter valve fully opened switch is not turned ON, despite the ECM commanding the intake shutter valve to open fully
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
Read freeze frame data using    
 Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running
or stopped, the engine was warmed up or not, etc. at the time of the malfunction.
1 CHECK INTAKE SHUTTER ASSY
(a) Visually check that the intake shutter valve moves within approximately 2 to 3 seconds after the ignition
switch is turned ON.
Intake shutterProceed to
Does not moveA
Smoothly move to full±open positionB
B Go to step 6
A

A31135Intake Shutter Assy
05±636
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
2CHECK INTAKE SHUTTER ASSY
(a)Check if the intake shutter valve moves as the lever is rotated by hand.
Intake shutterProceed to
Smoothly movedA
Difficult to move smoothlyB
BREPLACE INTAKE SHUTTER ASSY
(See page 10±61)
A
3INSPECT INTAKE SHUTTER ASSY
(a)Check the intake shutter for resistance. (1)Measure the resistance between the terminals.
RHD Resistance:
TerminalsTemperatureResistance
1 ± 2
1 ± 3at20
C(68
F)18to22
4 ± 5at 20
C (68
F)18 to 22

4 ± 6
LHD Resistance:
TerminalsTemperatureResistance
1 ± 3
2 ± 3at20
C(68
F)18to22
4 ± 6at 20
C (68
F)18 to 22

5 ± 6
NGREPLACE INTAKE SHUTTER ASSY
(See page 10±61)
OK

A66060
E13
ECM Connector
LU+A LU±A LU±B
E1
LU+B
E12
A56892
Signal Waveform
20 V/
Division
10 msec./Division
LU+A
LU+B
LU±BLU±A
A80456
E13
ECM Connector
LU+A
LU±A LU±B
LU+B
A56871
D1
Wire Harness Side
Intake shutter Connector
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±637
AVENSIS REPAIR MANUAL (RM1018E)
4INSPECT ECM(LU VOLTAGE)
(a)Inspect using the oscilloscope.
(b)During idling, check the waveform between the specified
terminals of the E12 and E13 ECM connectors.
Standard:
Symbols (Terminal No.)Specified condition
LU+A (E13±15) ± E1 (E12±7)
LU±A (E13±14) ± E1 (E12±7)CorrectwaveformisasshownLU+B (E13±13) ± E1 (E12±7)Correct waveform is as shown
LU±B (E13±12) ± E1 (E12±7)
NGREPLACE ECM (See page 10±65)
OK
5 CHECK HARNESS AND CONNECTOR(INTAKE SHUTTER ASSY ± ECM)
(a) Disconnect the D1 intake shutter connector.
(b) Disconnect the E13 ECM connector.
(c) Check for continuity between the wire harness side con- nectors.
Standard (Check for open):
Symbols (Terminal No.)Specified condition
LU+A (E13±15) ± Intake shutter (D1±6)
LU±A (E13±14) ± Intake shutter (D1±4)ContinuityLU+B (E13±13) ± Intake shutter (D1±3)Continuity
LU±B (E13±12) ± Intake shutter (D1±1)
Standard (Check for short):
Symbols (Terminal No.)Specified condition
LU+A (E13±15) or Intake shutter (D1±6) ± Body ground
LU±A (E13±14) or Intake shutter (D1±4) ± Body groundNo continuityLU+B (E13±13) or Intake shutter (D1±3) ± Body groundNo continuity
LU±B (E13±12) or Intake shutter (D1±1) ± Body ground
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

A81491
T3
Wire Harness Side
Intake Shutter Fully
Opened Switch Connector
A80456
E13
ECM ConnectorTHOP
05±638
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
6 READ VALUE OF HAND±HELD TESTER
(a) Connect the hand±held tester to the DLC3.
(b) Turn the ignition switch ON and push the hand±held tester main switch ON.
(c) Fully open the intake shutter valve by hand.
(d) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / ACCEL OPEN SWº and read its value
displayed on the hand±held tester.
Result:
Switch Condition DisplayedProceed to
OFFA
ONB
B CHECK DTC OUTPUT RECUR (DTC P0488 OUT-
PUT AGAIN)
HINT:
After clearing the DTC, start the engine and let it idle for 30 se-
conds and accelerate the vehicle speed to 60 km/h (37 mph)
with the accelerator pedal opened more than the half angle,
then confirm P0488 is not set again.
A
7 CHECK HARNESS AND CONNECTOR(FULLY OPENED SWITCH ± ECM)
(a) Disconnect T3 the intake shutter fully opened switch con-
nector.
(b) Disconnect the E13 ECM connector.
(c) Check for continuity between the wire harness side con-
nectors.
Standard (Check for open):
Symbols (Terminal No.)Specified condition
THOP (E13±11) ± Intake shutter (T3±1)Continuity
Standard (Check for short):
Symbols (Terminal No.)Specified condition
THOP (E13±11) or Intake shutter (T3±1) ± Body groundNo continuity
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK

± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±639
AVENSIS REPAIR MANUAL (RM1018E)
CHECK DTC OUTPUT RECUR (DTC P0488 OUTPUT AGAIN)
HINT:
After clearing the DTC, start the engine and let it idle for 30 seconds and accelerate the vehicle speed to
60 km/h (37 mph) with the accelerator pedal opened more than the half angle, then confirm P0488 is not
set again.

A81006
ECM
E3
EGR Valve Assy
G
EG+A 6
E12
Y±G
R±L
G±BE12
E12
E125
4
3EG±A
EG+B
EG±B 6
4
3
1From EFI MAIN Relay
5
2B±W
B±W
B±W
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±629
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0400 EXHAUST GAS RECIRCULATION FLOW
DTC P0403 EXHAUST GAS RECIRCULATION CONTROL
CIRCUIT
CIRCUIT DESCRIPTION
DTC No.DTC Detection ConditionTrouble Area
P0400Mass air flow rate is not changed when turning on EGR valve
EGR valve assy

Open or short in EGR circuit
P0403EGR valve assy motor malfunction

Oen or short in EGR circuit

EGR passage

ECM
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
Read freeze frame data using    
 Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running
or stopped, the engine was warmed up or not, etc. at the time of the malfunction.
05CPU±01

A82939
+B2
+B1EGR2
EGR1 EGR4
EGR3
05±630
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
1CHECK OTHER DTC OUTPUT(BESIDES P0400 AND/OR P0403)
(a)Read the DTC using the hand±held tester.
Result:
Display (DTC output)Proceed
P0400 and/or P0403 are outputA
P0400 and/or P0403 and other DTCs are outputB
HINT:
If any other codes besides P0400 and/or P0403 are output, perform the trou\
bleshooting for those DTCs first. BGO TO RELEVANT DTC CHART(See page 05±544)
A
2READ VALUE OF HAND±HELD TESTER(MASS AIR FLOW RATE)
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch ON and push the hand±held tester main switch \
ON.
(c)Start the engine.
(d)Warm up the engine, the engine coolant temperature should be above 75
C (167
F) and bellow 90
C
(194
F).
(e)Select the item ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / MAFº.
(f)Check that the MAF reading during idling. Result: MAF greater than 4 g/s but less than 16 g/s
(g)Force the EGR valve to operate with a hand±held tester, make the valve opening 0, and check that
the AFM reading during idling.
Result: MAF greater than 10 g/s but less than 16 g/s
NGREPLACE EGR VALVE ASSY (See page 14±286)
OK
3INSPECT EGR VALVE ASSY
(a)Check the EGR valve for resistance. (1)Measure the resistance between the specified ter-minals.
Resistance:
Terminal No.Specified condition
+B1 ± EGR119.6
1.4

+B1 ± EGR219.6
1.4

+B2 ± EGR319.6
1.4

+B2 ± EGR419.6
1.4

NGREPLACE EGR VALVE ASSY
(See page 14±286)
OK

A56871
E3
Wire Harness SideS2S1 S4
S3
EGR Valve Connector
A81087
E12
ECM Connector
EG+A
EG±A EG+BEG±B
A66060
E12
ECM Connector
EG+A
EG±A EG±B
E1
EG+B
A09818
Signal Waveform
10 V/
Division
GND
0.5 msec./Division
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±631
AVENSIS REPAIR MANUAL (RM1018E)
4CHECK HARNESS AND CONNECTOR(EGR VALVE ASSY ± ECM)
(a)Disconnect the E2 EGR valve connector.
(b)Disconnect the E12 ECM connector.
(c)Check for continuity between the wire harness side con-
nectors.
Standard (Check for open):
Symbols (Terminal No.)Specified condition
EG+A (E12±6) ± S3 (E3±6)
EG±A (E12±5) ± S1 (E3±4)ContinuityEG+B (E12±4) ± S4 (E3±3)Continuity
EG±B (E12±3) ± S2 (E3±1)
Standard (Check for short):
Symbols (Terminal No.)Specified condition
EG+A (E12±6) or S3 (E3±6) ± Body ground
EG±A (E12±5) or S1 (E3±4) ± Body groundNocontinuityEG+B (E12±4) or S4 (E3±3) ± Body groundNo continuity
EG±B (E12±3) or S2 (E3±1) ± Body ground
NGREPAIR OR REPLACE HARNESS OR CONNECTOR
OK
5INSPECT ECM(EGR VALVE ASSY VOLTAGE)
(a)Inspect using the oscilloscope.
(b)During idling, check the waveform between the specified terminals of the E12 ECM connector.
Standard:
Symbols (Terminal No.)Specified condition
EG+A (E12±6) ± E1 (E12±7)
EG±A (E12±5) ± E1 (E12±7)CorrectwaveformisasshownEG+B (E12±4) ± E1 (E12±7)Correct waveform is as shown
EG±B (E12±3) ± E1 (E12±7)
NGREPLACE ECM (See page 10±65)
OK

05±632
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
6CHECK DEPOSIT(EGR VALVE ASSY)
NGREMOVE FOREIGN OBJECT AND CLEAN EGR VALVE
OK
7CHECK DEPOSIT(EGR PASSAGE)
NGREPAIR OR REPLACE
OK
8CHECK FOR EXHAUST GAS LEAKS
NGREPAIR EXHAUST GAS LEAKAGE POINT
OK
REPLACE ECM (See page 10±65)

A81017
GeneratorGlow Plug ECMGLOW
Relay Battery
A81018
Ignition Switch
Glow Plug
Engine Speed
Starting EngineAfter Glow Time OFFOFF ON ON
OFF After Glow System
(sec.)
1
020
6840
104(
C)
(
F)
After Glow Time
Engine Coolant Temperature 120 05±622
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0380 GLOW PLUG/HEATER CIRCUIT ºAº
CIRCUIT DESCRIPTION
The glow plug is mounted inside the engine combustion room. To ensure efficient engine starting with a cold
engine, the ECM calculates time the current needs to flow into the glow plug depending on the engine cool-
ant temperature after the ignition switch is turned ON. The ECM then turns on the glow relay and permits
the current to flow into the glow plug. The glow plug is then heated and enhances fuel combustion with the
cold engine.
This DTC will be set if there is open in glow plug itself or its circuit.
The ECM performs the after glow for a certain period of time depending on the engine coolant temperature
after the engine has been started. After glow reduces a diesel engine knocking, a white smoke, and etc with
a cold engine.
05CPT±01