catalytic converter TOYOTA AVENSIS 2005 Service Owner's Manual

01±8
± INTRODUCTIONTERMS FOR MANUAL TRANSAXLE REPAIR MANUAL
C250 M/T REPAIR MANUAL (RM1020E) WU±OC
Warm Up Oxidation Catalytic Converter±
WU±TWCWarm Up Three±Way Catalytic ConverterManifold Converter
3GRThird Gear±
4GRFourth Gear±

A00798
Atmosphere
Housing
Platinum Electrode
Solid Electrolyte
(Zirconia Element)
Platinum Electrode
Heater
Coating (Ceramic)
Exhaust Gas CoverIdeal Air−Fuel Mixture
Output Voltage
Richer−Air Fuel Ratio−Leaner
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
05−83
AVENSIS Supplement (RM1045E)
CIRCUIT DESCRIPTION
To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three−way cata-
lytic converter is used. For the most efficient use of the three−way catalytic converter, the air−fuel ratio must
be precisely controlled so that it is always close to the stoichiometric air−fuel ratio.
The heated oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity
of the stoichiometric air−fuel ratio. This is used to detect the oxygen concentration in the exhaust gas and
to provide the ECM with feedback to control the air−fuel ratio.
When the air−fuel ratio becomes LEAN, the oxygen concentration in the exhaust gas increases. And the
heated oxygen sensor informs the ECM of the LEAN condition (low voltage, i. e. less than 0.45 V).
When the air−fuel ratio is RICHER than the stoichiometric air−fuel ratio, the oxygen concentration in the ex-
haust gas is reduced. And the heated oxygen sensor informs the ECM of the RICH condition (high voltage,
i. e. more than 0.45 V). The ECM judges whether the air−fuel ratio is RICH or LEAN by voltage from the
heated oxygen sensor, and controls the injection timing accordingly. However, if the malfunction of the
heated oxygen sensor causes abnormal voltage output, the ECM becomes unable to perform the accurate
air−fuel ratio control.
The heated oxygen sensors include a heater which heats the zirconia element. The heater is controlled by
the ECM. When the intake air volume is low (the temperature of the exhaust gas is low), the current flows
to the heater in order to heat the sensor for the accurate oxygen concentration detection.

−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
05 −37
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P0420 *3
(05 −1 74)
Catalyst System Efficiency Be-
low Threshold (Bank 1)SGas leakage in exhaust system
S Heated oxygen sensor
S Three −way catalytic converter (inside exhaust manifold)
ff
P0430 *3
(05 −1 74)
Catalyst System Efficiency Be-
low Threshold (Bank 2)SGas leakage in exhaust system
S Heated oxygen sensor
S Three −way catalytic converter (inside exhaust manifold)
ff
P0443
(05 −1 79)Evaporative Emission Control
System Purge Control Valve Cir-
cuitSOpen of short in VSV circuit for EVAP
S VSV for EVAP
S ECM
ff
P0500
(05 −1 83)Vehicle Speed Sensor ”A”
SCombination meter
S Open or short in speed sensor circuit
S Vehicle speed sensor
S ECM
S Skid control ECU
S Clutch or brake slips or gear is broken
ff
P0503
(05 −1 83)Vehicle Speed Sensor ”A”
Intermittent/Erratic/high
SCombination meter
S Open or short in vehicle speed sensor circuit
S Vehicle speed sensor
S ECM
S Skid control ECU
S Clutch or brake slips or gear is broken

f
P0504
(05 −1 85)Brake Switch Correlation
SShort in stop lamp switch signal circuit
S Stop lamp switch
S ECM

f
P0505 *3
(05 −1 89)Idle Air Control System
SElectric throttle control system
S Air induction system
S PCV hose connection
ff
P0555
(05 −1 91)Brake Booster Pressure Sensor
Circuit
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Vacuum hose
S ECM
ff
P0556
(05 −1 94)Brake Booster Pressure Sensor
Circuit Range/Performance
SVacuum hose (between the brake booster and intake manifold,
the brake booster and brake booster pressure sensor, and the
intake manifold and manifold absolute pressure sensor)
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Manifold absolute pressure sensor
S Brake booster
S Open or short in stop lamp switch circuit
S Stop lamp switch
S ECM
ff
P0557
(05 −1 91)Brake Booster Pressure Sensor
Circuit Low Input
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Vacuum hose
S ECM
ff
P0558
(05 −1 91)Brake Booster Pressure Sensor
Circuit High Input
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Vacuum hose
S ECM
ff
P0560
(05 −1 99)System VoltageSOpen in back −up power source circuit
S ECMff
P057 1
(*5)Brake Switch ”A” CircuitS Cruise control system
f
P0604
(05 −202)Internal Control Module Random
Access Memory (RAM) ErrorSECMff
P0606
(05 −202)ECM/PCM ProcessorSECMff

A91218
ECM Monitor ed
A/F Sens or Voltage
Air−Fuel Ratio
Solid Electrolyte
(Zirconia Element)
Cover Atmosphere
Exhaust Gas Flange
Platinum Electrode
Coating (Ceramic)
Heater
−
DIAGNOSTICS ECD SYSTEM (1CD−FTV)(From September, 2003)
05 −305
AVENSIS Supplement (RM1045E)
DTC P003 1 OXYGEN (A/F) SENSOR HEATER CONTROL
CIRCUIT LOW (BANK 1 SENSOR 1)
HINT:
S For more information on the A/F sensor and TOYOTA D −CAT (*1), see page 05 −255.
S If P0031 is present, refer to the diagnostic trouble codes (DTCs) table for the TOYOTA D −CAT on page
05 −255.
SThis DTC is related to the A/F sensor, although the caption is the oxygen sensor.
*1: Diesel Clean Advanced Technology.
CIRCUIT DESCRIPTION
The A/F sensor has the characteristic that it provides output voltage which is proportional to the existing air −
fuel ratio. The A/F sensor output voltage (*2) is used to provide the ECM with feedback to control the air −fuel
ratio.
The A/F sensor is located after the DPNR (*3) catalytic converter. This sensor has been developed based
on structure and technology of a sensor that is being used for gasoline engines. Its cover portion of the sen-
sor has been changed for application of use to the diesel engine with TOYOTA D −CAT in order to eliminate
influence of the sensor temperature and particulate matter (PM).
In order to reduce both PM and nitrogen oxides (NOx), the ECM adjusts the air −fuel ratio to slightly RICH
(but it is LEAN compared with a stoichiometric air −fuel ratio) with signals from the A/F sensor, if needed.
When the ECM exercises DPNR catalyst regeneration by adding fuel using the exhaust fuel addition injector,
the air −fuel ratio is also properly adjusted through the sensor.
*2: The voltage value changes inside the ECM only.
*3: Diesel Particulate −NOx Reduction system.
05I7J −01

05−302
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P0606
(05 −425)ECM/PCM Processor
ECM



P0607
(05 −425)Control Module Performance
SECM
ff
P0622
(05 −426)Generator Field ”F” Terminal Cir-
cuit
SOpen in generator (alternator) circuit
S Generator (alternator)
S Drive belt
S ECM
ff
P0627
(05 −429)Fuel Pump Control Circuit / Open
SOpen or shot in suction control valve circuit
S Suction control valve
S ECM
ff
P 1229
(05 −32 1)Fuel Pump System
S Short in supply pump (suction control valve) circuit
S Supply pump (suction control valve)
S ECM
ff
P 1238
(05 −43 1)Injector Malfunction
S Injector
S EDU (P0200 is set simultaneously)
S Open or short in engine wire harness (P0200 is set simulta-
neously)
S Connector connection (P0200 is set simultaneously)
S Compression pressure
S Valve clearance
S Valve timing
S ECM
ff
P 125 1
(05 −376)Turbo/Super Charger Overboost
Condition (Too High)
SVRV
S Open or short in VRV circuit
S Turbocharger
S EGR valve
S Vacuum hose
S ECM
ff
P 127 1
(05 −435)Fuel Regulator Circuit Malfunc-
tion (EDU Drive)
SOpen or short in pressure discharge valve circuit
S Open or short in pressure discharge valve itself
S EDU
S ECM
ff
P 1272
(05 −435)Fuel Pressure Regulator Mal-
function
SOpen or short in pressure discharge valve circuit (P 127 1is set
simultaneously)
S Pressure discharge valve
S Supply pump
S ECM
ff
P 1386
(05 −444)Injector For Exhaust Fuel Addi-
tion
SOpen or short in exhaust fuel addition injector circuit
S Exhaust fuel addition injector
S DPNR catalytic converter (Manifold converter sub −assy)
S Open in exhaust temperature sensor circuit
S A/F sensor
S Exhaust gas temperature sensor
S Supply pump assy
S Mass air flow meter
S Fuel leaks in exhaust fuel addition injector
S Main injector
S Cylinder compression pressure
S Valve clearance
S Valve timing
S Air intake system has blockages
S Air intake system has leakage
S Exhaust system has blockages
S Exhaust system has leakage
S EGR system has blockages
S EGR system has leakage
S ECM
ff

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −303
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P 1425
(05 −457)Differential Pressure Sensor Cir-
cuit
SOpen or short in differential pressure sensor circuit
S Incorrect arrangement differential pressure sensor hose piping
S Differential pressure sensor
S ECM
ff
P 1426
(05 −462)Differential Pressure Sensor
(Installation)
SIncorrect arrangement differential pressure sensor hose piping
S Differential pressure sensor vacuum hose is clogged
S Blockage in vacuum transmitting pipe sub −assy
S Differential pressure sensor
S ECM
ff
P 1427
(05 −457)Differential Pressure Sensor Cir-
cuit LowSOpen or short in differential pressure sensor circuit
S Incorrect arrangement differential pressure sensor hose pipingff
P 1428
(05 −457)Differential Pressure Sensor Cir-
cuit High
Incorrectarrangementdifferentialpressuresensorhosepiping
SDifferential pressure sensor
S ECMff
P 160 1
(05 −465)Injector Correction Circuit Mal-
function (EEPROM)SInjector compensation code
S ECMff
P 1611
(05 −425)IC Circuit MalfunctionSECMff
P2002
(05 −466)Particulate Trap Efficiency Below
Threshold (Bank 1)
SDPNR catalytic converter (manifold converter sub −assy)
S Differential pressure sensor
S Differential pressure sensor vacuum hose is clogged
S Blockage in vacuum transmitting pipe sub −assy
S Exhaust gas temperature sensor
S Exhaust gas leaks in TOYOTA D −CAT
S Mass air flow meter
S ECM
ff
P203 1
(05 −415)Exhaust Gas Temperature Sen-
sor Circuit (Bank 1Sensor 2)ff
P2032
(05 −415)Exhaust Gas Temperature Sen-
sor Circuit Low (Bank 1Sensor
2)S Open or short in exhaust gas temperature sensor (on down
stream) circuit
S Exhaust gas temperature sensor (on down stream)
ff
P2033
(05 −415)Exhaust Gas Temperature Sen-
sor Circuit High (Bank 1Sensor
2)
gp()
S ECM
ff
P2047
(05 −470)Reductant Injector Circuit/Open
(Bank 1Unit 1)SOpen in exhaust fuel addition injector circuit
S Exhaust fuel addition injector
S ECM
ff
P2 120
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D” CircuitSOpen or short in accelerator pedal position sensor circuit
S Accelerator pedal position sensor
S ECM
ff
P2 121
(05 −479)Throttle/Pedal Position Sensor/
Switch ”D” Circuit Range/Perfor-
manceSAccelerator pedal position sensor circuit
S Accelerator pedal position sensor
S ECM
ff
P2 122
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D” Circuit Low Inputff
P2 123
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D” Circuit High Inputff
P2 125
(05 −473)Throttle/Pedal Position Sensor/
Switch ”E” Circuit
SOpen or short in acceleratorpedalposition sensor circuitff
P2 127
(05 −473)Throttle/Pedal Position Sensor/
Switch ”E” Circuit Low Input
SOpenorshortinacceleratorpedalpositionsensorcircuit
SAccelerator pedal position sensor
S ECMff
P2 128
(05 −473)Throttle/Pedal Position Sensor/
Switch ”E” Circuit High Inputff
P2 138
(05 −473)Throttle/Pedal Position Sensor/
Switch ”D”/”E” Voltage Correla-
tion
ff

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

A85344
TOYOTA D−CAT Diagram:
DCAT
Switch
EDU
ECM
Common RailInjector
Fuel Tank EGR Valve
FReduces NOx (Linear Solenoid Type)EGR Cooler
FCools Down EGR GasExhaust Fuel Addition
Injector
FReduces NOxEGR Cooler Catalyst
FMaintains proper operation of EGR cooler
Differential Pressure
Sensor
Exhaust Gas
Temperature Sensor
FMonitors catalyst
A/F Sensor
Oxidation Catalytic Converter
FReduces HC and CO Manifold Converter Sub−assy
(DPNR Catalytic Converter)
FReduces NOx, PM, HC, and CO Intake Shutter (Throttle Valve)
Supply Pump
FSupplies fuel to exhaust fuel addition injector
temperature FDPNR catalyst regeneration
FSupplies high pressure fuel to main injector via common rail
Pressure Discharge Valve
Fuel Pressure sensor
05−256
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
2. TOYOTA D−CAT DESCRIPTION
(a)TOYOTA D−CAT:
Diesel Clean Advanced Technology (TOYOTA D−CAT) comprehensively regulates engine control (consists
of a catalytic system and a fuel injection system) that purifies both particulate matter (PM) and nitrogen ox-
ides (NOx) discharged by diesel engines.
The catalytic system purifies hydrocarbons (HC) and carbon monoxides (CO), and reduces PM and NOx
with a catalytic converter with the Diesel Particulate−NOx Reduction system (DPNR). The fuel injection sys-
tem adds fuel into the exhaust port using the exhaust fuel addition injector to produce RICH state for NOx
reduction and maintain a proper catalyst temperature for DPNR catalyst regeneration.

− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−257
AVENSIS Supplement (RM1045E)
(b)TOYOTA D−CAT COMPONENTS:
ComponentDescription
DPNR catalytic converterReduces HC, CO, PM, and NOx.
Exhaust fuel addition in-
jectorAdds fuel into the exhaust port in order to produce RICH air−fuel ratio for NOx reduction. Also, raises catalyst temper-
ature for DPNR catalyst regeneration.
Exhaust gas temperature
sensorUsed for estimating DPNR catalytic converter temperature and adjusting fuel addition by ECM while DPNR catalyst
regeneration is performed. Also, detects DPNR catalytic converter temperature to prevent the catalytic converter
temperature from rising too high.
Differential pressure sen-
sorDetects the volume of PM deposits in and incorrect vacuum hose arrangement on the DPNR catalytic converter.
A/F sensorUsed for controlling air−fuel ratio. By controlling the air−fuel ratio, combustion control for low temperature combustion
and DPNR catalyst regeneration are properly regulated.

DTC No.
( ): Potential DTCs
( F )
ABCDE F G HI JKL MNOPQ RS T
P003 1 (See page 05 −305)
P0544 (See page 05 −415)
P0545 (See page 05 −415)
P0546 (See page 05 −415)
P 1386 (See page 05 −444)
P 1425 (See page 05 −457)
P 1426 (See page 05 −462)
P 1427 (See page 05 −457)
P 1428 (See page 05 −457)
P2002 (See page 05 −466)
P203 1 (See page 05 −415)
P2032 (See page 05 −415)
P2033 (See page 05 −415)
P2047 (See page 05 −470)
P2238 (See page 05 −484)
P2239 (See page 05 −484)
F
F
F F
F
F FF
FF F F FFF
FF
F
F
F
F FF
F
F
F
F F F
F
F
F
FFF
F (
F )(F)
( F )
(F )(F )(F ) (
F )(F )
( F )
F
F
F F
F
F
(F )(
F )
( F )
( F )(
F )
F F F
F
( F )
( F )(F)( F)
05
−258
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
(c) DIAGNOSTICS TROUBLE CODES (DTCS) TABLE FOR TOYOTA D −CAT:
HINT:
This table indicates typical DTC combinations for each malfunction occurrence.
Trouble AreaMalfunctionRefer to
DPNR catalytic converterDeteriorated or cloggedA
Stuck openB
Stuck closeC
Eha stfeladditioi jectoLow fuel addition volumeDExhaust fuel addition injectorOpen in exhaust fuel addition injector circuitE
Short in exhaust fuel addition injector circuitF
Open or short in exhaust fuel addition injectorG
Open in exhaust gas temperature sensor circuitH
Exhaust gas temperature sensorShort in exhaust gas temperature sensor circuitIExhaustgastemperaturesensor
Exhaust gas temperature sensorJ
Open in differential pressure sensor circuitK
Short in differential pressure sensor circuitL
DifferentialpressuresensorDifferential pressure sensorMDifferential pressure sensorDifferential pressure sensor cloggedN
Incorrect vacuum hose arrangement of the differ-
ential pressure sensorO
A/Fse soOpen or short in A/F sensor or heater circuitPA/F sensorA/F sensorQ
Exhaust gas leaksExhaust gas leaksR
Fuel leaksFuel leaks in fuel addition injectorS
Supply pumpCorrect fuel pressure cannot be fed to the ex-
haust fuel addition injectorT