code TOYOTA AVENSIS 2005 Service Repair Manual

05−328
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
DTC P0093 FUEL SYSTEM LEAK DETECTED − LARGE
LEAK
HINT:
S If DTC P 1229 is detected, P0093 (fuel leaks in high −pressurized area) may be detected simultaneous-
ly. Because of the extremely high internal fuel pressure in the common rail opens the pressure limiter,
and the ECM may interpret this as a fault and set P0093.
S For more information on the common rail system, see page 05 −255.
S If P0093 is present, refer to the diagnostic trouble codes (DTCs) table for the fuel system on page
05 −255.
CIRCUIT DESCRIPTION
Refer to the description on page 05 −255.
DTC No.DTC Detection ConditionTrouble Area
P0093Fuel leaks in high −pressurized area
( 1 trip detection logic)
SFuel line between supply pump and common rail
S Fuel line between common rail and injector
S Supply pump
S Common rail
S Injector (P 1238 is set simultaneously)
S Pressure discharge valve
S Open or short in EDU circuit (P0200 is set simultaneously)
S Open or short in injector circuit (P0200 and P 1238 are set
simultaneously)
S EDU (P0200 is set simultaneously)
S ECM
HINT:
After confirming DTC P0093, check the internal fuel pressure of the common rail in the ”DIAGNOSIS / OBD/
MOBD / DATA LIST / ALL / COMN RAIL” using the hand −held tester.
Reference:
Engine SpeedFuel Pressure (MPa)
IdlingApproximately 30 to 40
2,500 rpm (No engine load)Approximately 50 to 100
MONITOR DESCRIPTION
P0093 (Fuel leaks in high −pressurized area):
This DTC stands for fuel leaks that are existing in high −pressurized area in the common rail system. The
ECM constantly monitors the internal fuel pressure of the common rail after the engine is started, and the
ECM then will set this DTC if the drop of the internal fuel pressure is large when injecting the fuel.
In the common rail system, high −pressurized fuel, approximately 30 to 180 MPa (306 to 1,835 kgf/cm
2, 4,35 1
to 26, 106 psi), is always applied to the high −pressurized area including the supply pump, common rail, injec-
tor and piping. The ECM adjusts the suction control valve control current (by applying duty ratio signal) to
obtain the target internal fuel pressure.
If this DTC is present, the ECM enters the fail −safe mode. The fail −safe mode suspends both fuel injection
and supply pump operation, and then stops the engine. Before stopping the engine, the ECM permits driving
the vehicle for 1minute. The fail −safe mode continues until the ignition switch is turned to OFF.
MONITOR STRATEGY
Required sensorsFuel pressure sensor
Frequency of operationContinuous
Duration1 second
CHK ENG operation1driving cycle
05CPF −05

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −329
AVENSIS Supplement (RM 1045E)
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
Engine speed600 rpm−
The monitor will not run if the fuel pressure sensor, suction control valve circuit, or pressure discharge valve is malfunctioning
TYPICAL MALFUNCTION THRESHOLDS
Threshold
Drop of the internal fuel pressure is large when injecting fuel
INSPECTION PROCEDURE
HINT:
Read 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 OTHER DTC OUTPUT(IN ADDITION TO DTC P0093)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES”.
(d) Read DTCs. Result:
Display (DTC output )Proceed to
P0093A
P0093 and P 1238B
P0093 and P0200 and/or P 127 1C
HINT:
If any other codes besides P0093 are output, perform troubleshooting for those DTCs first.
B Go to step 3
C GO TO RELEVANT DTC CHART(See page 05 −299)
A
2 CHECK FUEL LEAKAGE(IN HIGH −PRESSURIZED FUEL PARTS AND AREA)
(a) Visually check the supply pump, injector and fuel line located between the supply pump and common
rail for fuel leaks or fuel pressure leaks. Also, perform the same on the fuel line between the common
rail and the injector (see page 11− 67, 11− 46).
HINT:
There is possibility that fuel leaks inside the components (supply pump, etc) have been occurred.
NG REPAIR OR REPLACE
OK

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −32 1
AVENSIS Supplement (RM 1045E)
DTC P0088 FUEL RAIL/SYSTEM PRESSURE − TO O
HIGH
DTC P 1229 FUEL PUMP SYSTEM
HINT:
S For more information on the supply pump (suction control valve) and the common rail system,
see page 05 −255.
S If P0088 and/or P 1229 is present, refer to the diagnostic trouble codes (DTCs) table for the fuel system
on page 05 −255.
CIRCUIT DESCRIPTION
Refer to the description on page 05 −255.
DTC No.DTC Detection ConditionTrouble Area
P0088
SInternal fuel pressure of the common rail is too high:
The fuel pressure exceeds 200 MPa (2,039 kgf/cm2, 29,007
psi)
( 1 trip detection logic)
SSupply pump (Suction control valve)
S Pressure discharge valve
S Short in supply pump (Suction control valve) circuit
S Open in pressure discharge valve circuit
S ECM
P 1229
SFuel over −feed:
Internal fuel pressure is beyond the target fuel pressure de-
spite the ECM closing the suction control valve
( 1 trip detection logic)SShort in supply pump (Suction control valve) circuit
S Supply pump (Suction control valve)
S ECM
HINT:
After confirming DTC P0088 and P 1229, check the fuel rail pressure in the ”DIAGNOSIS / OBD/MOBD /
DATA LIST / ALL / COMN RAIL” using the hand −held tester.
Reference:
Engine SpeedFuel Pressure (MPa)
IdlingApproximately 30 to 40
2,500 rpm (No engine load)Approximately 50 to 100
MONITOR DESCRIPTION
P0088 (Internal fuel pressure too high):
The ECM will set this DTC if the fuel pressure inside the common rail is beyond 200 MPa (2,039 kgf/cm
2,
29,007 psi). This DTC indicates that the suction control valve may be stuck open, or there may be short in
its circuit, and the pressure discharge valve may be stuck closed, or there may be open in its circuit.
If this DTC is present, the ECM enters the fail −safe mode and limits the engine power. The fail −safe mode
continues until the ignition switch is turned to OFF.
P 1229 (Fuel over −feed):
The ECM will set this DTC if the actual fuel pressure inside the common rail stays higher than the target fuel
pressure, despite the ECM closing the suction control valve. This DTC represents that the suction control
valve may be stuck open, or there may be short in its circuit. Under this condition, the pressure discharge
valve operates frequently.
If this DTC is present, the ECM enters the fail −safe mode and limits the engine power. The fail −safe mode
continues until the ignition switch is turned to OFF.
05CPE −03

05−324
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
1 CHECK OTHER DTC OUTPUT(IN ADDITION TO DTC P0088 AND/OR P 1229)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES”.
(d) Read DTCs.
Result:
Display (DTC output)Proceed to
P0088, or P0088 and P 1229A
P 1229B
P0 190, P0 191,P0 192, P0 193 and/or P 127 1C
P1272D
B Go to step 4
C GO TO RELEVANT DTC CHART
(See page 05 −299)
D Go to step 3
A
2 READ OUTPUT DTC(SEE IF DTC P 1272 IS OUTPUT)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CLEAR CODES”.
(d) Clear the DTCs.
(e) Start the engine and turn the ignition switch to OFF. Wait for 10 seconds and then restart the engine
and turn the ignition switch to OFF again.
(f) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES”.
(g) Read DTCs. Result:
Display (DTC output)Proceed to
P1272A
No outputB
B Go to step 4
A
3 REPLACE COMMON RAIL ASSY(PRESSURE DISCHARGE VALVE) (See page 11− 67)
GO
CHECK IF DTCS OUTPUT RECUR (DTC P0088 AND/OR P 1229 OUTPUT AGAIN)
HINT:
After clearing the DTCs, drive the vehicle at 50 km/h (3 1mph) for 5 minutes, and then confirm that P0088
and/or P 1229 is not present again.

A75346
Suction
Control
Valve
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DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −325
AVENSIS Supplement (RM 1045E)
4 INSPECT INJECTION OR SUPPLY PUMP ASSY(SUCTION CONTROL VALVE)
(a) Measure the resistance between the terminals of the suc-
tion control valve.
Standard: 1.9 to 2.3
at 20 _C (68 _F)
NG REPLACE INJECTION OR SUPPLY PUMP ASSY (SUCTION CONTROL VALVE)
(See page 11− 58)
OK
5 READ OUTPUT DTC(SEE IF DTC P 1229 IS OUTPUT)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CLEAR CODES”.
(d) Clear the DTCs.
(e) Disconnect the suction control valve connector and then start the engine. Wait for 1 minute.
HINT:
If the engine does not start, the suction control valve is normal. Therefore proceed to step 6.
(f) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES”.
(g) Read DTCs. Result:
Display (DTC output)Proceed to
No outputA
P1229B
B REPLACE INJECTION OR SUPPLY PUMP ASSY
(SUCTION CONTROL VALVE)
(See page 11− 58)
A

05−314
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
DTC P0087 FUEL RAIL/SYSTEM PRESSURE − TO O
LOW
DTC P0 190 FUEL RAIL PRESSURE SENSOR CIRCUIT
DTC P0 192 FUEL RAIL PRESSURE SENSOR CIRCUIT
LOW INPUT
DTC P0 193 FUEL RAIL PRESSURE SENSOR CIRCUIT
HIGH INPUT
HINT:
S For more information on the fuel pressure sensor and the common rail system, see page 05 −255.
SIf P0087, P0 190, P0 192 and/or P0 193 is present, refer to the diagnostic trouble codes (DTCs) table
for fuel system on page 05 −255.
05CPD −05

A80452
PCR1E
13
ECM Connector
E
12PCR2
E2VCS
E2S
VC
A84808
E2
F
16
Wire Harness Side:
Front View
VCS
PRE2S
VC
Fuel Pressure Sensor Connector
PR2
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −319
AVENSIS Supplement (RM 1045E)
2 CHECK IF DTCS OUTPUT RECUR(FUEL PRESSURE SENSOR DTCS)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CLEAR CODES”.
(d) Clear the DTCs.
(e) Let the engine idle for 60 seconds, and repeat quick engine RPM acceleration (to 2,500 rpm) for 30 seconds.
(f) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES”.
(g) Read DTCs.
Result:
Display (DTC output)Proceed to
P0087, P0 190, P0 192 and/or P0 193A
No outputB
B CHECK FOR INTERMITTENT PROBLEMS
(See page 05 −270)
A
REPLACE ECM (See page 10− 29)
3 CHECK HARNESS AND CONNECTOR(FUEL PRESSURE SENSOR − ECM)
(a) Disconnect the E 12 and E 13 ECM connectors.
(b) Disconnect the F 16 fuel pressure sensor connector.
(c) Check the resistance between the wire harness side con-
nectors.
Standard (Check for open):
Tester ConnectionSpecified Condition
PCR1(E 13− 26) −PR (F 16− 5)
PCR2 (E 13− 33) −PR2 (F 16− 2)
VCS (E 12− 2) −VCS (F 16−1 )Below1
VC (E 13−1 8)−VC (F 16− 6)Below 1

E2 (E 13− 28) −E2 (F 16− 4)
E2S (E 12−1 )− E2S (F 16− 3)
Standard (Check for short):
Tester ConnectionSpecified Condition
PCR 1(E 13− 26) or PR (F 16− 5) −Body ground
PCR2 (E 13− 33) or PR2 (F 16 − 2) −Body ground
VCS (E 12− 2) or VCS (F 16−1 )− Body ground10k
orhigherVC (E 13−1 8) or VC (F 16− 6) −Body ground10k
or higher
E2 (E 13− 28) or E2 (F 16− 4) −Body ground
E2S (E 12−1 ) or E2S (F 16− 3) −Body ground
(d) Reconnect the ECM connectors.
(e) Reconnect the fuel pressure sensor connector.

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

054JD−11
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −299
AVENSIS Supplement (RM 1045E)
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Parameters listed in the chart may be different than your readings depending on the type of instrument used
and other factors.
During the DTC check, refer to the table below if a malfunction code is displayed. For details about each
code, refer to the page number in the DTC Chart’s left column.
DTC No.
(See Page)Detection ItemTrouble Area* 1
CHK ENGMemory
P003 1
(05 −305)Oxygen (A/F) Sensor Heater
Control Circuit Low (Bank 1Sen-
sor 1)SOpen in A/F sensor heater circuit
S A/F sensor heater
S A/F sensor heater relay
S ECM
ff
P0045
(05 −312)Turbo/Super Charger Boost Con-
trol Solenoid Circuit / OpenSVRV
S Open or short in VRV circuit
S ECM
ff
P0087
(05 −314)Fuel Rail/System Pressure −To o
LowS Open or short in fuel pressure sensor circuit
S Fuel pressure sensor
S ECM
ff
P0088
(05 −32 1)Fuel Rail/System Pressure −To o
High
S Supply pump (Suction control valve)
S Pressure discharge valve
S Short in supply pump (Suction control valve) circuit
S Open in pressure discharge valve circuit
S ECM
ff
P0093
(05 −328)Fuel System Leak Detected −
Large Leak
S Fuel line between supply pump and common rail
S Fuel line between common rail and injector
S Supply pump
S Common rail
S Injector (P 1238 is set simultaneously)
S Pressure discharge valve
S Open or short in EDU circuit (P0200 is set simultaneously)
S Open or short in injector circuit (P0200 and P 1238 are set
simultaneously)
S EDU (P0200 is set simultaneously)
S ECM
ff
P0095
(05 −33 1)Intake Air Temperature Sensor 2
Circuit
S Open or short in diesel turbo inlet air temperature sensor cir-ff
P0097
(05 −33 1)Intake Air Temperature Sensor 2
Circuit Low
SOpenorshortindieselturboinletairtemperaturesensorcir-
cuit
S Diesel turbo inlet air temperature sensor
ff
P0098
(05 −33 1)Intake Air Temperature Sensor 2
Circuit High
p
S ECMff
P0 100
(05 −336)Mass or Volume Air Flow Circuit
SOpen or short in mass air flow meter circuit
S Mass air flow meter
S ECM
ff
P0 101
(05 −34 1)Mass or Volume Air Flow Circuit
Range/Performance ProblemS Mass air flow meterff
P0 102
(05 −336)Mass or Volume Air Flow Meter
Circuit Low InputSOpen or short in mass air flow meter circuit
SMassairflowmeter
ff
P0 103
(05 −336)Mass or Volume Air Flow Meter
Circuit High InputSMass air flow meter
S ECM
ff
P0 105
(05 −342)Manifold Absolute Pressure/
Barometric Pressure Circuit
SOpen or short in manifold absolute pressure sensor circuit
S Manifold absolute pressure sensor
S Turbocharger assembly
S EGR valve assembly
S ECM
ff
P0 106
(05 −346)Manifold Absolute Pressure/
Barometric Pressure Circuit
Range/Performance Problem
SManifold absolute pressure sensorff

−
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