TOYOTA AVENSIS 2005 Service Repair Manual

A90876
D22
Front View
Wire Harness Side:
Differential pressure
Sensor Connector
VP
VC
GND
A8 1088
E 13
ECM Connector
E
12
PEX
VC
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −46 1
AVENSIS Supplement (RM 1045E)
4 CHECK HARNESS AND CONNECTOR(DIFFERENTIAL PRESSURE SENSOR −
ECM)
(a) Disconnect the D22 differential pressure sensor connec-
tor.
(b) Disconnect the E 12 and E 13 ECM connectors.
(c) Check the resistance between the wire harness side con- nectors.
Standard (Check for open):
Tester ConnectionSpecified Condition
PEX (E 12− 20) − VP (D22 −2)
VC (E 13−1 8)− VC (D22 −3)Below 1

E2 (E 13− 28) − GND (D22 −1 )
Standard (Check for short):
Tester ConnectionSpecified Condition
PEX (E 12− 20) or VP (D22 −2) − Body ground10 k
or higherVC (E 13−1 8) or VC (D22 −3) − Body ground10k
or higher
(d) Reconnect the differential pressure sensor connector.
(e) Reconnect the ECM connectors.
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
REPLACE DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14−1 08)

05−444
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
DTC P 1386 INJECTOR FOR EXHAUST FUEL ADDITION
HINT:
S For more information on the exhaust fuel addition injector and TOYOTA D −CAT (* 1), see page
05 −255.
S If P 1386 is present, refer to the diagnostic trouble codes (DTCs) table for TOYOTA D −CAT on page
05 −255.
S”Learning value” used in here represents a correction learning value of the fuel addition volume to raise
the DPNR (*2) catalyst temperature to a target range.
* 1 : Diesel Clean Advanced Technology.
*2: Diesel Particulate −NOx Reduction system.
05I8 1−01

A85355
Exhaust Fuel
Addition Injector
Injector Spray Supply PumpExhaust Gas
Temperature
Sensor (on up stream)
ECM Exhaust
Gas
Exhaust Gas Temperature
Sensor (on down stream)
Exhaust Fuel Addition InjectorA/F Sensor DPNR Catalytic
Converter
Turbocharger
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−445
AVENSIS Supplement (RM1045E)
CIRCUIT DESCRIPTION
The exhaust fuel addition injector is mounted on the exhaust port of the cylinder head, and low pressure is
provided to the injector by the feed pump in the supply pump. This injector adds fuel by a control signal from
the ECM.
This injector is used for two different controls: DPNR catalyst regeneration and nitrogen oxides (NOx) reduc-
tion.
Under the DPNR catalyst regeneration control, the injector adds fuel to raise a catalyst temperature.
In the other control, the injector helps the air−fuel ratio become RICH. As a result, NOx in the exhaust gas
will be reduced in response to the RICH air−fuel ratio.

05−446
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E) DTC No.
DTC Detection ConditionMain Trouble AreaRelated Trouble Area
SExcess or low fuel addition volume from exhaust
fuel addition injector:
When air−fuel ratio deviates from a value estimated
by ECM while the injector adds fuel
(1trip detection logic)SOpen in exhaust temperature
sensor circuit
SA/F sensor
SExhaust gas temperature sensor
SSupply pump assy
SMass air flow meter
SFuelleaksinexhaustfueladdi-
P1386
SLow fuel addition volume from exhaust fuel addition
injector:
When learning value (*3) exceeds standard level
(1trip detection logic)SOpen or short in exhaust fuel
addition injector circuit
SExhaust fuel addition injector
SDPNR catalytic converter (Man-
ifold converter sub−assy)
SFuelleaksinexhaustfueladdi-
tion injector
SMain injector
SCylinder compression pressure
SValve clearance
SValve timing
Airintakesystemhasblockages
SExhaust fuel addition injector nozzle stuck open:
When air−fuel ratio becomes RICHER than standard
level, or exhaust gas temperature reaches higher
than standard level
(1trip detection logic)
SAir intake system has blockages
SAir intake system has leakage
SExhaust system has blockages
SExhaust system has leakage
SEGR system has blockages
SEGR system has leakage
SECM
*3: Correction learning value of the fuel addition volume to raise the DPNR catalyst temperature to a target
range.
HINT:
DTC P2047 (Reductant injector circuit/open [bank1unit1]) will be present if there is an open malfunction in
the exhaust fuel addition injector circuit.

− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
05−447
AVENSIS Supplement (RM1045E)
MONITOR DESCRIPTION
HINT:
”Learning value” used in here represents a correction learning value of the fuel addition volume to raise the
DPNR (*4) catalyst temperature to a target range.
*4: Diesel Particulate−NOx Reduction system.
In order to detect malfunction in the exhaust fuel addition injector, the ECM monitors: the air−fuel ratio, DPNR
catalytic temperature and learning value.
SWhen the exhaust fuel addition injector adds fuel during NOx reduction, the ECM monitors the air−fuel
ratio when the exhaust fuel addition injector adds fuel. If the air−fuel ratio is too RICH or too LEAN
against the ECM predetermined air−fuel ratio, the ECM judges the fuel addition volume small or large,
and illuminates the CHK ENG. In this malfunction, there is no fail−safe operation.
SThe ECM always monitors the DPNR catalytic converter temperature and the air−fuel ratio. When the
temperature reaches higher than its usual level or the air−fuel ratio becomes extremely RICH, the ECM
judges that the injector has stuck open and illuminates the CHK ENG. If this malfunction occurs, the
ECM enters the fail−safe mode to limits its acceptable vehicle speed to approximately10 km/h (6 mph)
at maximum by restraining the engine power.
SUnder DPNR catalyst regeneration, the ECM monitors the learning value. Normally, the learning value
for the DPNR catalyst regeneration is in the vicinity of1.0. Thus the learning value is at1.4 or more
for a certain period of time, the ECM judges the fuel addition volume from the injector insufficient and
illuminates the CHK ENG. If this malfunction occurs, the ECM enters the fail−safe mode to limit its ac-
ceptable vehicle speed to approximately 80 km/h (50 mph) at maximum by restraining the engine pow-
er.
Malfunction Condition by Fail−Safe Operation:
Fail−Safe OperationMalfunction ConditionMalfunction Detection ConditionDrive Pattern
No fail−safe operation
Low or excess fuel
addition volume from
the exhaust fuel addi-
tion injectorWhen the exhaust fuel addition injector adds fuel during NOx
reduction, if actual air−fuel ratio deviates from a value esti-
mated by the ECM when the exhaust fuel addition injector
adds fuel
After engine warm−up, per-
form DPNR REJU (PM) in
the ACTIVE TEST menu us-
ing the hand−held tester,
and drive at constant vehicle
speed within 50 to100 km/h
(31to 62 mph) for more than
15 minutes
Limits engine power by
permitting driving at ve-
hicle speed of approxi-
mately10 km/h (6 mph)
at maximum
Exhaust fuel addition
injector has stuck
openDPNR catalytic converter temperature reaches higher than
800_C(1,472_F) or air−fuel ratio is less than approximately
12 for a couple of secondsIdling engine for more than 5
minutes (*5)
Limits engine power by
permitting driving at ve-
hicle speed of approxi-
mately 80 km/h (50 mph)
at maximum
(HINT: DPNR catalyst re-
generation is prohibited)
Low fuel addition vol-
ume from the exhaust
fuel addition injectorUnder DPNR catalyst regeneration, when learning value of
1.4 or more continues for a certain period of time (*6)
After engine warm−up, per-
form DPNR REJU (PM) in
the ACTIVE TEST menu us-
ing the hand−held tester,
and drive at constant vehicle
speed within 50 to100 km/h
(31to 62 mph) for more than
30 minutes
*5: The DPNR catalytic converter temperature will not reach 800_C(1,472_F) or higher during idling even
if the exhaust fuel addition injector has stuck open.
*6: While the DPNR catalyst regeneration is exercised, the ECM raises the DPNR catalytic converter temper-
ature to more than approximately 600_C(1,112_F) by adding fuel using the exhaust fuel addition injector.
If the temperature does not reach that temperature regardless of the attempt, the correction learning value
of the fuel addition volume increments to raise the DPNR catalytic converter temperature to a target range.

A91206
Malfunction Detection:
Abnormal
(Low Volume)ON
OFF
Time
DPNR
Catalyst
Regeneration
(Activation of Fuel Addition)
Normal
A/F Ratio
Learning ValueLean
Rich
Abnormal
(Excess Volume)
Abnormal
(Low Volume)
Abnormal
(Excess Volume)
Threshold
OFF
HighLow
DPNR
Catalytic Converter
Temperature
(Exhaust Gas Temperature)
Normal (More than 600
_ C[ 1,11 2_ F])
Detect P 1386
05 −448
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
WIRING DIAGRAM
Refer to DTC P2047 on page 05 −470.
INSPECTION PROCEDURE
HINT:
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.
S”Learning value” used in here represents a correction learning value of the fuel addition volume to raise
the DPNR catalyst temperature to a target range.

−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −449
AVENSIS Supplement (RM 1045E)
1 CHECK OTHER DTC OUTPUT(IN ADDITION TO P 1386)
(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
P1386A
P 1386 and other DTCsB
HINT:
If any other codes besides P 1386 are output, perform troubleshooting for those DTCs first.
B GO TO RELEVANT DTC CHART(See page 05 −299)
A
2 CHECK FAIL −SAFE CONDITION
(a) Check the condition of fail −safe operation while the CHK ENG is being illuminated.
Result:
Condition of Fail −Safe OperationProceed to
Permits driving at vehicle speed of approximately 10 km/h (6
mph) at maximumA
Permits driving at vehicle speed of approximately 80 km/h
(50 mph) at maximumB
No fail −safe operationC
B Go to step 7
C Go to step 4
A
3 READ VALUE OF HAND −HELD TESTER(EXHAUST GAS TEMPERATURE)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON. (Do not start the engine)
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / EX TEMP (IN)” and ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / EX TEMP (OUT)” and read its value displayed on the hand −held tes-
ter.
Result:
Temperature DisplayedProceed to
OK (Same value as actual exhaust gas temperature)A
1 ,000 ˚C( 1,832 ˚F )B
HINT:
If there is a open circuit, the hand −held tester indicates 1,000 ˚C( 1,832 ˚F).

05−450
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
B GO TO DTC P0544, P0545, P0546, P203 1, P2032
AND P2033 (RELATED TO EXHAUST GAS TEM-
PERATURE SENSOR) (See page 05 −415)
A
4 PERFORM ENGINE RPM ACCELERATION(WHITE SMOKE AND FUEL SMELL)
CAUTION:
Stop the engine immediately if you observe that there is white smoke or a fuel smell during the follow-
ing inspection. Fuel may be leaked from the exhaust fuel addition injector.
(a) Remove the battery cable for 1minute, and then reconnect the cable.
(b) After the engine starts, promptly accelerate the engine to approximately 3,000 rpm with no load 3
times.
(c) Check for white smoke in exhaust gases.
(d) Check for a smell in exhaust gases.
Result:
ResultProceed to
Other than aboveA
Either white smoke or fuel smells in exhaust gasesB
B Go to step 17
A
5 READ VALUE OF HAND −HELD TESTER(A/F RATIO)
CAUTION:
Stop the engine immediately if you observe that there is white smoke or a fuel smell during the follow-
ing inspection. Fuel may be leaked from the exhaust fuel addition injector.
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Start the engine.
(d) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / AF FT B 1S1”.
(e) Read the air −fuel ratio displayed on the tester after 3 −minute idling.
Result:
A/F RatioProceed to
More than 12A
Less than 12B
B Go to step 17
A

1
2
A8 1503
Component Side:
E16
Exhaust Fuel Addition Injector
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −45 1
AVENSIS Supplement (RM 1045E)
6 READ VALUE OF HAND −HELD TESTER(EXHAUST GAS TEMPERATURE)
CAUTION:
Stop the engine immediately if you observe that there is white smoke or a fuel smell during the follow-
ing inspection. Fuel may be leaked from the exhaust fuel addition injector.
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Start the engine.
(d) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / EX TEMP (IN) and EX TEMP (OUT)”.
(e) Check that exhaust gas temperature is within the specification below.
Result:
ConditionExhaust Gas Temperature ( _ C)
Idling after engine warm −upConstant at approximately 50 to 700 ( 122 to 1,292 _ F)
NG GO TO DTC P0544, P0545, P0546, P203 1, P2032
AND P2033 (RELATED TO EXHAUST GAS TEM-
PERATURE SENSOR) (See page 05 −415)
OK
7 READ VALUE OF HAND −HELD TESTER(A/F RATIO)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Start the engine.
(d) Select the item ”DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / AF FT B 1 S1”.
(e) After warming up the engine, check if the air −fuel ratio varies when accelerating the engine from idling
to 3,000 rpm by fully depressing the accelerator pedal 3 times.
Result:
Air −fuel RatioProceed to
VariesOK
Not varies onceNG
NG GO TO DTC P2237, P2238 AND P2239
(RELATED TO A/F SENSOR) (See page 05 −484)
OK
8 INSPECT EXHAUST FUEL ADDITION INJECTOR ASSY(RESISTANCE)
(a) Disconnect the E 16 exhaust fuel addition injector connec-
tor.
(b) Measure the resistance between the terminals of the ex-
haust fuel addition injector.
Standard:
Tester ConnectionSpecified Condition
1−211.6 to 12.4
at 20 _C (68 _F)
(c) Reconnect the exhaust fuel addition injector connector.

2
1
A80992
E 16
Front View
Wire Harness Side:
Exhaust Fuel Addition
Injector Connector
FIV
A80456
E13
ECM Connector FIV
05
−452
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
NG REPLACE EXHAUST FUEL ADDITION
INJECTOR ASSY (See page 14−1 66)
OK
9 CHECK HARNESS AND CONNECTOR(EXHAUST FUEL ADDITION INJECTOR −
ECM)
(a) Disconnect the E 16 exhaust fuel addition injector connec-
tor.
(b) Disconnect the E 13 ECM connector.
(c) Check the resistance between the wire harness side con-
nectors.
Standard (Check for open):
Tester ConnectionSpecified Condition
FIV (E 13− 3) −(E 16−1 )Below1
E2 (E 13− 28) −(E 16− 2)Below 1

Standard (Check for short):
Tester ConnectionSpecified Condition
FIV (E 13− 3) or (E 16−1 )− Body ground10k
or higher
(d) Reconnect the exhaust fuel addition injector connector.
(e) Reconnect the ECM connector.
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
1 0 CHECK FUEL LEAKAGE(IN EXHAUST FUEL ADDITION INJECTOR)
(a) Visually check if there is no fuel leak between the supply pump and exhaust fuel addition injector.
HINT:
SPrimary pressure of maximum 1MPa ( 10 kgf/cm2, 145 psi) is provided from a feed pump inside the
supply pump to the exhaust fuel addition injector.
SThere is possibility that fuel leaks inside the components (supply pump, etc) have been occurred.
NG REPAIR OR REPLACE
OK