engine TOYOTA AVENSIS 2005 Service Repair Manual

A80362
VSV is ON VSV is OFFE
F
E
F
Air
A18294
E13
ECM Connector
E01
EVP1E12
05–156
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
INSPECTION PROCEDURE
HINT:
Read freeze frame data using the intelligent tester II. Freeze frame data record the engine condition\
when
malfunctions are detected. When troubleshooting, freeze frame data can h\
elp determine if the vehicle was
moving or stationary, 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 PERFORM ACTIVE TEST USING INTELLIGENT TESTER II(EVAP VSV)
(a) Disconnect the vacuum hose of the EVAP VSV.
(b) Connect the intelligent tester II to the DLC3.
(c) Start the engine and turn the intelligent tester II ON.
(d) Select the following menu items: Powertrain / Engine and ECT / Active Test / Purge VSV. Press the right or left but-
ton.
(e) Check if the disconnected port applies suction to your fin-
ger when operating the EVAP VSV using the intelligent
tester II.
Standard:
Tester OperationSpecified Condition
VSV is ONApplies suction to your finger
VSV is OFFApplies no suction to your finger
(f) Reconnect the vacuum hose.
OK CHECK FOR INTERMITTENT PROBLEMS (See page 05–9 )
NG
2 INSPECT ECM(CHECK VOLTAGE)
(a) Turn the ignition switch to ON.
(b) Measure the voltage between the terminals of the E12 and E13 ECM connectors.
Standard:
Tester ConnectionSpecified Condition
EVP1 (E12–19) – E01 (E13–7)9 to 14 V
OK REPLACE ECM (See page 10–65 of Pub. No. RM1018E AVENSIS)
NG
3 INSPECT VACUUM SWITCHING VALVE(OPERATION OF EVAP VSV)
OK: Air flows when the battery voltage is applied to the EVAP VSV. NG REPLACE VACUUM SWITCHING VALVE
OK

A65745
E12
EVP1 ECM Connector
0A52933
Wire Harness Side:
EVAP VSV Connector
V5
A66053
Engine Room R/B No. 4:EFI Relay
0A52933
Wire Harness Side:
EVAP VSV Connector
V5
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–157
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
4 CHECK HARNESS AND CONNECTOR(ECM – EVAP VSV)
(a) Disconnect the E12 ECM connector.
(b) Disconnect the V5 EVAP VSV connector.
(c) Check the resistance.
Standard (Check for open):
Tester ConnectionSpecified Condition
EVAP VSV (V5–2) – EVP1 (E12–19)Below 1 Ω
Standard (Check for short):
Tester ConnectionSpecified Condition
EVAP VSV (V5–2) or PRG (E12–19) – Body ground10 kΩ or higher
(d) Reconnect the ECM connector.
(e) Reconnect the EVAP VSV connector.
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
5 CHECK HARNESS AND CONNECTOR(EFI RELAY – EVAP VSV)
(a) Remove the EFI relay from the engine room R/B No. 4.
(b) Disconnect the V5 EVAP VSV connector.
(c) Check the resistance. Standard (Check for open):
Tester ConnectionSpecified Condition
EVAP VSV (V5–1) – EFI relay (3)Below 1 Ω
Standard (Check for short):
Tester ConnectionSpecified Condition
EVAP VSV (V5–1) or EFI relay (3) – Body ground10 kΩ or higher
(d) Reinstall the EFI relay
(e) Reconnect the EVAP VSV connector.
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
INSPECT ECM POWER SOURCE CIRCUIT ( See page 05–195)

A82718
Signal Length
Time
Sensor
Output
Voltage
Heated Oxygen Sensor Signal Length:
A58686
Vehicle Speed
70 km/h
(44 mph)
Ignition Switch OFF 40 seconds
or more
Engine coolant temperature is more than 75
C (167 F)
20 seconds
or more 40 seconds
or more
40 seconds
or more
(g) (h)
Idling (e) (g)
(h) (g)
(h)
20 seconds
or more 20 seconds
or more
Once
Twice
At least 8 times
2 minutes
or more
(a), (b) and (c)
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–151
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)DTC No.
DTC Detecting ConditionTrouble Area
P0420
After engine and TWC are warmed up, and while vehicle is
driven within predetermined vehicle speed and engine speed
range:
Waveforms of heated oxygen sensor (sensor 2) frequently
fluctuates between rich and lean (2 trip detection logic)
Gas leakage in exhaust system
 Heated oxygen sensor (sensor 1)
 Heated oxygen sensor (sensor 2)
 Three–way catalytic converter (TWC)
CONFIRMATION DRIVING PATTERN
(a) Connect the intelligent tester II to the DLC3.
(b) Turn the ignition switch to ON and turn the intelligent tester ll ON.
(c) Switch the ECM from normal mode to check mode using the intelligent test\
er ll ( see page 05–20).
(d) Start the engine.
(e) Allow the engine to idle for 2 minutes.
(f) Warm up the engine until the engine coolant temperature reaches more than\
75 C (167 F).
(g) Drive the vehicle at 70 km/h (44 mph) or more for 40 seconds or more.
(h) Stop the vehicle and allow the engine to idle for 20 seconds or more.
(i) Repeat the steps (g) and (h) at least 8 times in one driving cycle.
HINT:
If a malfunction exists, the MIL will be illuminated during step (i).

05–152
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
NOTICE:
If the conditions in this test are not strictly followed, no malfunction\
will be detected. If you do not
have the intelligent tester II, turn the ignition switch to OFF after perfor\
ming steps from (d) to (i), then
perform steps (d) to (i) again.
WIRING DIAGRAM
Refer to DTC P0130 on page 05–74.
INSPECTION PROCEDURE
HINT:
Read freeze frame data using the intelligent tester II. Freeze frame data record the engine condition\
when
malfunctions are detected. When troubleshooting, freeze frame data can h\
elp determine if the vehicle was
moving or stationary, 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 P0420)
(a) Connect the intelligent tester II to the DLC3.
(b) Turn the ignition switch to ON and turn the intelligent tester ll ON.
(c) Select the following menu items: Powertrain / Engine and ECT / DTC.
(d) Read DTCs.
Result:
Display (DTC Output)Proceed To
P0420A
P0420 and other DTCsB
HINT:
If any DTCs other than P0420 are output, troubleshoot those DTCs first.
B GO TO RELEVANT DTC CHART (See page 05–27 )
A
2 CHECK FOR EXHAUST GAS LEAKAGE
OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST GASLEAKAGE POINT
OK
3 INSPECT HEATED OXYGEN SENSOR(SENSOR 1) ( See page 05–74)
NG REPLACE HEATED OXYGEN SENSOR
OK

–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–153
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
4 INSPECT HE ATED OXYGEN SENSOR(SENSOR 2) ( See page 05–100)
OK: During air–fuel ratio feedback, the oxygen sensor output fluctuat\
es between rich and lean.
NG REPLACE HEATED OXYGEN SENSOR
OK
REPLACE THREE–WAY CATALYTIC CONVERTER (BOTH FRONT AND REAR TWC)
NOTICE:
On the damaged bank, replace both the front and rear catalysts.
HINT:
Intelligent tester II only:
Malfunctioning areas can be found by performing the Active Test / A/F Control operation. The A/F Control
operation can determine if the heated oxygen sensor or other potential trouble ar\
eas are malfunctioning or
not.
(a) Perform the Active Test using the intelligent tester II.
HINT:
The A/F Control operation lowers the injection volume by 12.5 % or incre\
ases the injection volume by 25
%. (1) Connect the intelligent tester II to the DLC3.
(2) Start the engine and turn the intelligent tester II ON.
(3) Warm up the engine by running the engine at 2,500 rpm for approximately 3\
minutes.
(4) On the intelligent tester II, select the following menu items: Powertrain \
/ Engine and ECT / ActiveTest / A/F Control.
(5) Select the following monitor items: O2S B1 S1 and O2S B1 S2.
(6) Perform the A/F Control operation with the engine in an idling condition\
(press the right or left
button).
Result:
The heated oxygen sensor reacts in accordance with increases and decreases \
of the injection
volume:
+25 % → Rich output: More than 0.5 V
–12.5 % → Lean output: Less than 0.4 V
NOTICE:
Sensor 1 (front sensor) has an output delay of a few seconds. Sensor 2 (rea\
r sensor) has a maximum
output delay of approximately 20 seconds.

A63955
GND
CH1
(G2+)
CH2
(NE+) GND
05–140
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0340 CAMSHAFT POSITION SENSOR ”A” CIRCUIT (BANK 1 OR SINGLE SENSOR)
DTC P0341 CAMSHAFT POSITION SENSOR ”A” CIRCUIT RANGE/PERFORMANCE (BANK 1
OR SINGLE SENSOR)
CIRCUIT DESCRIPTION
The Camshaft Position (CMP) sensor consists of a magnet and an iron core which is wrapped with coppe\
r
wire, and is installed on the cylinder head. When the camshaft rotates, each \
of 3 teeth on the camshaft
passes through the CMP sensor. This activates the internal magnet in the sensor, generating a voltage in
the copper wire. The camshaft rotation is synchronized with the crankshaft rotation. When the crankshaft
turns twice the voltage is generated 3 times in the CMP sensor. The generated voltage in the sensor acts
as a signal, allowing the ECM to locate the camshaft position. This signal is then used to con\
trol ignition tim-
ing, fuel injection timing, and the VVT system.
DTC No.DTC Detection ConditionTrouble Area
P0340
No camshaft position sensor signal to ECM during cranking
(2 trip detection logic)Open or short in camshaft position sensor circuit
 Camshaft position sensor
Camshaft timing pulleyP0340(2 trip detection logic)
No camshaft position sensor signal to ECM at engine speed
of 600 rpm or more (1 trip detection logic)Camshaft timing pulley
 Jumped tooth of timing chain
 ECM
P0341While crankshaft rotates twice, camshaft position sensor signal
is input to ECM 12 times or more (1 trip detection logic)
Open or short in camshaft position sensor circuit
 Camshaft position sensor
 Camshaft timing pulley
 Jumped tooth of timing chain
 ECM
HINT:
DTC P0340 indicates a malfunction related to the CMP sensor (+) circuit (the wi\
re harness between
the ECM and CMP sensor, and the CMP sensor itself).
DTC P0341 indicates a malfunction related to the CMP sensor (–) cir\
cuit (the wire harness between
the ECM and CMP sensor, and the CMP sensor itself).
Reference: Inspection using the oscilloscope.
HINT:
The correct waveform is as shown on the left.
G2+ stands for the camshaft position sensor signal, and
NE+ stands for the crankshaft position sensor signal.
ItemContents
TerminalCH1: G2+ – NE–
CH2: NE+ – NE–
Equipment Setting5V/Division, 20ms/Division
ConditionDuring cranking or idling
WIRING DIAGRAM
Refer to DTC P0335 on page 05–136.
05B5J–14

A64984Camshaft Position Sensor Component Side:
– DIAGNOSTICSSFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–141
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
INSPECTION PROCEDURE
HINT:
Read freeze frame data using the intelligent tester II. Freeze frame data record the engine condition when
malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was
moving or stationary, 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 INSPECT CAMSHAFT POSITION SENSOR(RESISTANCE)
(a) Disconnect the C1 camshaft position sensor connector.
(b) Measure the resistance between the terminals of the
camshaft position sensor.
Standard:
Tester ConnectionSpecified Condition
1 – 2835 to 1,400 Ω at cold
1 – 21,060 to 1,645 Ω at hot
NOTICE:
Terms ”cold” and ”hot” refer to the temperature of the
coils. ”Cold” means approximately –10 to 50C (14 to
122F). ”Hot” means approximately 50 to 100C (122 to
212F).
(c) Reconnect the camshaft position sensor connector.
NG REPLACE CAMSHAFT POSITION SENSOR
(See page 18–5 of Pub. No. RM1018E AVENSIS)
OK

A85286
GND KNK1 Signal Waveform 05–132
– DIAGNOSTICSSFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0325 KNOCK SENSOR 1 CIRCUIT (BANK 1 OR
SINGLE SENSOR)
DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT
(BANK 1 OR SINGLE SENSOR)
DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT
(BANK 1 OR SINGLE SENSOR)
CIRCUIT DESCRIPTION
The flat type knock sensor (non–resonant type) has a structure that can detect vibration in a wider band of
frequency, from about 6 kHz to 15 kHz and has the following features:
The knock sensor is fitted on the cylinder block to detect engine knocking.
The sensor contains a piezoelectric element which generates voltage when it becomes deformed. This
occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, the ignition timing
is retarded to suppress it.
DTC No.DTC Detecting ConditionTrouble Area
P0325Knock sensor signal level remains at low for more than 10
secondsOpen or short in knock sensor circuit
Knock sensor (under–torqued or looseness)
ECM
P0327Output voltage of the knock sensor is 0.5 V or less
Short in knock sensor circuit
Knock sensor
ECM
P0328Output voltage of the knock sensor is 4.5 V or more
Open in knock sensor circuit
Knock sensor
ECM
HINT:
If the ECM detects DTC P0325, P0327 and/or P0328, it enters fail–safe mode in which the corrective re-
tarded angle value is set to the maximum value.
Reference: Inspection by using the oscilloscope.
The correct waveform is as shown.
ItemContents
TerminalKNK1 – EKNK
Equipment Setting0.01 to 10 V/Division,
0.01 to 10 msec./Division
ConditionAfter warming up the engine,
keep the engine speed at 4,000 rpm
05JOG–03

A96003
K1
Knock Sensor1 (Shielded)
J/C J5
J51
E12 ECM
KNK1
EH
2
E122
EKNK
BB
J65 V
W
J6
EE D
EB1
EB1
2
1
D
BR BR
W
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–133
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
Read freeze frame data using the intelligent tester II. Freeze frame data record the engine condition\
when
malfunctions are detected. When troubleshooting, freeze frame data can h\
elp determine if the vehicle was
moving or stationary, 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 READ OUTPUT DTC
(a) Clear the DTC(s) ( see page 05–18).
(b) Warm up the engine.
(c) Run the engine at 3,000 rpm for 10 seconds or more.
(d) Connect the intelligent tester II to the DLC3.
(e) Turn the ignition switch to ON and turn the intelligent tester II ON.
(f) Select the following menu items: Powertrain / Engine and ECT / DTC.
(g) Read DTCs. Result :
Display (DTC Output)Proceed To
P0325A
P0325, and P0327 and/or P0328B
No outputC
B Go to step 3
C CHECK FOR INTERMITTENT PROBLEMS (See page 05–9 )
A

05–118
– DIAGNOSTICSSFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE
DETECTED
DTC P0301 CYLINDER 1 MISFIRE DETECTED
DTC P0302 CYLINDER 2 MISFIRE DETECTED
DTC P0303 CYLINDER 3 MISFIRE DETECTED
DTC P0304 CYLINDER 4 MISFIRE DETECTED
CIRCUIT DESCRIPTION
When a misfire occurs in the engine, hydrocarbons (HC) enter the exhaust gas in high concentrations. If this
HC concentration is high enough, there could be an increase in exhaust emission levels. High concentra-
tions of HC can also cause temperature of the catalyst to increase, possibly damaging the catalyst. To pre-
vent this increase in emissions and limit the possibility of thermal damage, the ECM monitors the misfire rate.
When the temperature of the catalyst reaches a point of thermal degradation, the ECM will blink the MIL.
For monitoring misfire, the ECM uses both the camshaft position sensor and the crankshaft position sensor.
The camshaft position sensor is used to identify misfiring cylinders and the crankshaft position sensor is used
to measure variations in the crankshaft rotation speed. The misfire counter increments when crankshaft rota-
tion speed variations exceed threshold values.
If the misfiring rate exceeds the threshold and could cause emission deterioration, the ECM illuminates the
MIL.
HINT:
For any particular 200 revolutions of the engine, misfiring which could result in overheating of the cata-
lyst is detected. This will cause the MIL to blink (1 trip detection logic).
For any particular 1,000 revolutions of the engine, misfiring which could result in emission deterioration
is detected. This will cause the MIL to illuminate (2 trip detection logic).
05KOH–02