alternator TOYOTA AVENSIS 2005 Service Owner's Manual

05I7Z−01
A91210
Engine Control System Diagram:
Accelerator Pedal
Position Sensor
Ignition Switch Signal
Starter Signal
Vehicle Speed Signal
DLC3Supply Pump
Pressure Discharge Valve Fuel Pressure Sensor
EDU Relay
EDU
Atmospheric
Temperature
Sensor
Glow
Plug Relay
Crankshaft Position SensorCamshaft
Position
SensorCommon Rail Suction Control Valve
Alternator Duty SignalDCAT Switch
ECM
Atmospheric
Pressure
Sensor
A/F Sensor Heater
Mass Air Flow Meter
Differential
Pressure Sensor
A/F Sensor Actuator
E−VRV
Exhaust Gas Temperature Sensor
(Up Stream)
Exhaust Gas Temperature Sensor
(Down Stream)Glow Plug EGR Valve
Injector
Turbo Pressure
Sensor
Engine Coolant
Temperature Sensor
Intake Air
Temperature
Sensor
Fuel Temperature Sensor
EGR Cooler Inter Cooler
Exhaust Fuel
Addition
Injector
DPNR Catalytic Converter
Turbocharger
(INJT and PRD Signal)
(INJF Signal)
Intake Shutter
(Throttle Valve)
Oxidation Catalytic
Converter
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−255
AVENSIS Supplement (RM1045E)
SYSTEM DESCRIPTION
1. ENGINE CONTROL SYSTEM

A81017
Generator (Alternator)Glow Plug
ECM
Glow
Plug
Relay
Battery
Duty Ratio
05
−426
−
DIAGNOSTICS ECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
DTC P0622 GENERATOR FIELD ”F” TERMINAL CIRCUIT
CIRCUIT DESCRIPTION
While the generator (alternator) is generating current, a duty ratio is sent from terminal M of the generator
to the ECM terminal ALT. This duty ratio is used for detecting an open malfunction of the generator circuit
and DTC P0380.
HINT:
DTC P0380 is prepared for indicating an open or short malfunction in the glow plug circuit. If this DTC is de-
tected, inspect the glow plug circuit. (See page 05 −386)
DTC No.DTC Detection ConditionTrouble Area
P0622
No duty ratio from terminal M of the generator (alternator) at
the engine running
(1 trip detection logic)SOpen in generator (alternator) circuit
S Generator (alternator)
S Drive belt
S ECM
HINT:
After confirming DTC P0622, check the internal fuel pressure of the common rail in the ”DIAGNOSIS / OBD/
MOBD / DATA LIST / ALL / GENERATOR” using the hand −held tester.
Result:
Engine SpeedGenerator Duty Ratio (%)
Idling10 to 100
When increasing engine speedGenerator duty ratio drops
When decreasing engine speedGenerator duty ratio rises
MONITOR DESCRIPTION
The ECM will detect a generator (alternator) failure or an open malfunction of the circuit, if the duty ratio is
not output from terminal M of the generator (alternator) despite running the engine.
MONITOR STRATEGY
Required SensorsGenerator (alternator) circuit
Frequency of operationContinuous
Duration10 seconds
CHK ENG Operation1 driving cycle
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
Battery voltage11 V−
Engine speed700 rpm2,000 rpm
05DW0 −02

A80456
E13
ALT
ECM Connector
A81490
A11
Wire Harness Side: Generator (alternator) Connector
Front View
−
DIAGNOSTICS ECD SYSTEM (1CD−FTV)(From September, 2003)
05 −427
AVENSIS Supplement (RM1045E)
TYPICAL MALFUNCTION THRESHOLDS
Threshold
There is no duty ratio output from terminal M of the generator (alternator)
WIRING DIAGRAM
Refer to DTC P0380 on page 05 −386.
INSPECTION PROCEDURE
HINT:
SIf different DTCs related to different systems that have terminal E2 as the ground terminal are output
simultaneously, terminal E2 may have an open circuit.
SRead 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 IF CHARGE LAMP IS ILLUMINATED
HINT:
Run the engine at 2,000 rpm, and check if the charge lamp located in the combination meter remains illumi-
nated.
YES Go to step 3
NO
2 CHECK HARNESS AND CONNECTOR(GENERATOR (ALTERNATOR) −ECM)
(a) Disconnect the E13 ECM connector.
(b) Disconnect the A11 generator (alternator) connector.
(c) Check the resistance between the wire harness side con-
nectors.
Standard (Check for open):
Tester ConnectionSpecified Condition
ALT (E13 −8) −M (A11 −3)Below 1

Standard (Check for short):
Tester ConnectionSpecified Condition
ALT (E13 −8) or M (A11 −3) −Body ground10 k
or higher
(d) Reconnect the ECM connector.
(e) Reconnect the generator (alternator) connector.
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

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

141ND−01
A57063
Measure Point for Belt
Deflection and Tension
Alternator
Crankshaft Compressor
P/SP/S
Alternator Crankshaft
A/C Equipped
A/C Not Equipped
−
ENGINE MECHANICAL ENGINE (1CD−FTV)(From September, 2003)
14 −87
AVENSIS Supplement (RM1045E)
ENGINE (1CD −FTV)(From September, 2003)
INSPECTION
1. INSPECT ENGINE COOLANT (See page 16 −15)
2. INSPECT ENGINE OIL (See page 17 −9)
3. INSPECT BATTERY (See Pub. No. RM1018E on page 19 −26)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB −ASSY
5. INSPECT DRIVE BELT
(a) Inspect the vane pump V −ribbed belt.
(1) Measure the belt deflection.
Pressing force: 98 N (10 kgf, 22 lbf)
New Belt
mm (in.)Used Belt mm (in.)
A/C Equipped8.0 to 10.5
(0.31 to 0.41)10.5 to 12.5
(0.41 to 0.49)
A/C Not Equipped10 to 12
(0.39 to 0.47)14 to 17
(0.55 to 0.67)
(2) Measure the belt tension.
New Belt
N (kgf, lbf)Used Belt
N (kgf, lbf)
A/C Equipped647 to 843
(66 to 86, 145 to 189)441 to 637
(45 to 65, 99 to 143)
A/C Not Equipped686 to 784
(70 to 80, 154 to 176)294 to 441
(30 to 45, 66 to 99)
NOTICE:
SCheck the drive belt deflection at the specified point.
SWhen installing a new belt, set its tension value as
specified.
SWhen inspecting the belt which has been used for
over 5 minutes, apply the specifications of ”Used
Belt.”
SWhen reinstalling the belt which has been used for
over 5 minutes, adjust its deflection and tension to
the intermediate value of each specification of ”Used
Belt.”
SThe V −ribbed belt tension and deflection should be
checked after 2 revolutions of engine cranking.
SWhen using a belt tension gauge, confirm the accura-
cy by using a master gauge first.