code TOYOTA AVENSIS 2005 Service Manual PDF

05CPA±01
05±526
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
PRECAUTION
1. Since each injector has a characteristic fuel injecting behavior, the ECM compensates such be-
havior by adjusting an injection time for each injector to optimize the fuel injection volume.
Compensating data for the optimum injection volume, which has converted into a 30±digit±al-
phanumeric value, has been imprinted on a head potion of the injector as the injection com-
pensation code.
2. The injection compensation code will be required to register to the ECM when replacing the in-
jectors or the ECM.
3. If an incorrect injection compensation value was registered to the ECM, the engine assembly
may rattle or the engine idling may be rough. In addition, it may be a cause of the engine failure
or short±life.

05±524
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
9SYMPTOM SIMULATION
10DTC CHECK (See page 05±528)
AMalfunction code
BNo code
BGO TO STEP 12
A
11DTC CHART (See page 05±544)
GO TO STEP 14
12BASIC INSPECTION (See page 05±528)
AWrong parts not confirmed
BWrong parts confirmed
BGO TO STEP 17
A
13PROBLEM SYMPTOMS TABLE (See page 05±551)
AWrong circuit confirmed
BWrong parts confirmed
B GO TO STEP 17
A
14CHECK ECM POWER SOURCE CIRCUIT (See page 05±686)
15 CIRCUIT INSPECTION
AMalfunction not confirmed
BMalfunction confirmed
B GO TO STEP 18
A

P0087 (See page 05±557)
P0088 (See page 05±563)
P0093 (See page 05±570)
P0190 (See page 05±557)
P0192 (See page 05±557)
P0193 (See page 05±557)
P0200 (See page 05±604)
P0627 (See page 05±655) P1229 (See page 05±563)
P1271 (See page 05±663) P1272 (See page 05±663) P1238 (See page 05±658) DTC No. A
BCDE F
GH IJKL
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P0191 (See page 05±603)


( ): Potential DTC codes
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05±522
±
DIAGNOSTICS ECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
6. DIAGNOSTICS TROUBLE CODE MATRIX FOR FUEL SYSTEM
HINT:
This matrix indicates typical DTC codes combinations for each malfunctio\
n occurrence.
Trouble areaMalfunctionRefer to
Open or short in injector circuitA
InjectorStuck openBj
Stuck closeC
Fuel pressure sensorOpen or short in fuel pressure sensor circuit or
pressure sensor output fixedD
Open or short in pressure discharge valve circuitE
Pressure discharge valveStuck openFg
Stuck closeG
Open or short in suction control valve circuitH
Suction control valveStuck openI
Stuck closeJ
EDUFaulty EDUK
Common rail system (Fuel system)Fuel leaks in high±pressure areaL
7. DIAGNOSTICS TROUBLE CODE DESCRIPTION
DTC No.Description
P0087Fuel pressure sensor output status at fixed value
P0088Internal fuel pressure too high (200 MPa (2,039 kgf/cm2, 29,007 psi) or more)
P0093Fuel leaks in high±pressure area
P0190Open or short in fuel pressure sensor circuit (Low or high output)
P0191Fuel pressure sensor out of range (Low output)
P0192Open or short in fuel pressure sensor circuit (High output)
P0193Open or short in fuel pressure sensor circuit (Sensor 1 and/or 2 relati\
on)
P0200Open or short in EDU or injector circuit
P0627Open or short in suction control valve circuit
P1229Fuel over fed
P1238Injection malfunction, exclude open or short in injector circuit
P1271Open or short in pressure discharge valve circuit
P1272Closed malfunction of the pressure discharge valve

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±597
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0116ENGINE COOLANT TEMPERATURE CIRCUIT
RANGE/PERFORMANCE PROBLEM
CIRCUIT DESCRIPTION
Refer to DTC P0115 on page 05±593.
DTC No.DTC Detection ConditionTrouble Area
P0116
When THW greater than ±40 \fC (±40 \fF) and less than 60 \fC
(140 \fF), and THA greater than ±6.7 \fC (20 \fF), and when start-
ing engine, conditions (a) and (b) continue (2 trip detection
logic):
(a)Vehicle speed is changing (Not stable)
(b)THW change is lower than 3 \fC (5.4 \fF) after engine was
started.

Cooling system

Engine coolant temperature sensor

Thermostat
In case that reading value of engine coolant temp. sensor will
not change more than 1 \fC (1.8 \fF) even after repeating 6 trips
(detection logic) of adjusting speed pattern with THW more
than 90 \fC (194 \fF) after engine was started.
INSPECTION PROCEDURE
HINT:

If DTCs ºP0115, P0116, P0117and P0118º are output simultaneously, engine coolant temperature
sensor circuit may be open or short. Perform the troubleshooting of DTC ºP0\
115, P0117 or P0118º first.

Read freeze frame data using \b
 . Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, it is useful for d\
etermining whether the vehicle
was running or stopped, the engine was warmed up or not, the air±fuel ra\
tio was lean or rich, etc. at
the time of the malfunction.
1CHECK OTHER DTC OUTPUT(BESIDES DTC P0116)
(a)Read the DTC using the hand±held tester. Result:
Display (DTC output)Proceed to
Only P0116 are outputA
P0116 and other DTCs are outputB
HINT:
If any other codes besides ºP0116º are output, perform the troubleshooting for those DTCs first.
BGO TO RELEVANT DTC CHART(See page 05±544)
A
2INSPECT THERMOSTAT (See page 16±39)
NGREPLACE THERMOSTAT (See page 16±50)
OK
REPLACE ENGINE COOLANT TEMPERATURE SENSOR
05CPN±01

05±588
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0106MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT RANGE/
PERFORMANCE PROBLEM
CIRCUIT DESCRIPTION
Refer to DTC P0105 on page 05±584.
DTC No.DTC Detection ConditionTrouble Area
P0106Voltage output of the manifold absolute pressure sensor is out
of the standard range. (2 trip detection logic)
Manifold absolute pressure sensor
INSPECTION PROCEDURE
HINT:

If DTCs ºP0105, P0107,and P0108º are output simultaneously, manifold absolute pressure sensor
circuit may be open or short. Perform the troubleshooting of DTC ºP0105, P01\
07 or P0108º first.

Read freeze frame data using \b
 . Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, it is useful for d\
etermining whether the vehicle
was running or stopped, the engine was warmed up or not, etc. at the time o\
f the malfunction.
1CHECK OTHER DTC OUTPUT(BESIDES DTC P0106)
(a)Read the DTC using the hand±held tester. Result:
Display (DTC output)Proceed to
Only P0106 are outputA
P0106 and other DTCs are outputB
HINT:
If any other codes besides ºP0106º are output, perform the troublesh\
ooting for those DTCs first.
BGO TO RELEVANT DTC CHART(See page 05±544)
A
REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR
05CPK±01

05±570
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0093FUEL SYSTEM LEAK DETECTED ± LARGE LEAK
HINT:

For more information on the common rail system, see page 05±517.

If P0093 is present, use the diagnostic trouble code matrix for fuel sys\
tem, see page 05±517.
CIRCUIT DESCRIPTION
Refer to description on page 05±517.
DTC No.DTC Detection ConditionTrouble Area
P0093Fuel leaks in high±pressure area.

Fuel line between supply pump and common rail

Fuel line between common rail and injector

Supply pump

Common rail

Injector (P1238 is set simultaneously)

Pressure discharge valve

Open or short in EDU circuit (P0200 is set simultaneously 

Open or short in injector circuit (P0200 and P1238 are set
simultaneously)

EDU (P0200 is set simultaneously 

ECM
HINT:
After confirming DTC P0093, use the hand±held tester to confirm the fuel rail pressure fro\
m the ºDIAGNOSIS
/ OBD/MOBD / DATA LIST / ALL / COMN RAIL PRESSº.
Engine SpeedFuel Pressure (MPa)
IdlingApprox. 30 to 40
Running the engine at 2,500 rpm (No engine load)Approx. 50 to 100
MONITOR DESCRIPTION
P0093 (Fuel leaks in high±pressure area):
This DTC stands for fuel leaks is existing in high±pressure area in the c\
ommon 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 decreasing rate of the internal fuel press\
ure is large when injecting the fuel.
In the common rail system, high±pressure fuel (approx. 30 to 180 MPa (\
306 to 1,835 kgf/cm
2, 4.351 to
26,106 psi)) is always applied to the high±pressure area including the su\
pply pump, common rail, injector
and piping. The ECM adjusts the suction control valve opening angle to obtain the target internal fuel pres-
sure.
If this DTC is present, the ECM enters fail±safe mode and permits drivi\
ng the vehicle for extra 1 minute before
stopping both the fuel injection and supply pump operation, then stops the engine\
. The fail±safe mode will
continue until the ignition switch is turned OFF.
MONITOR STRATEGY
Required sensorsFuel pressure sensor
Frequency of operationContinuous
Duration1 sec.
CHK ENG operation1 driving cycle
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
Engine speed600 rpm±
The monitor will not run if the fuel pressure sensor, or suction control valve circuit, or pressure discharge valve is malfu\
nct ioning
05CPF±01

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±571
AVENSIS REPAIR MANUAL (RM1018E)
TYPICAL MALFUNCTION THRESHOLDS
Threshold
Drop rate in the internal fuel pressure is large when injecting fuel
INSPECTION PROCEDURE
HINT:
Read freeze frame data using \b
 . Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determi\
ning whether the vehicle was running
or stopped, the engine was warmed up or not, etc. at the time of the malfu\
nction.
1CHECK OTHER DTC OUTPUT(BESIDES DTC P0093)
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch ON and push the hand±held tester main switch \
ON.
(c)Select the item ºDIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODESº.\
(d)Read the DTCs.
Result:
Display (DTC output besides DTC P0093)Proceed to
Only DTC P0093 is outputA
DTC P1238 is outputB
DTC ºP0200 and/or P1271º are outputC
HINT:
If any other codes besides ºP0093º are output, perform the troublesh\
ooting for those DTCs first.
BGo to step 3
CGO TO RELEVANT DTC CHART (See page 05±544)
A
2CHECK FUEL LEAKAGE(INSPECT HIGH±PRESSURE FUEL PARTS AND AREA FOR FUEL LEAKS)
(a)Visually check the supply pump, injector and fuel line located between the suppl\
y pump and the com-
mon rail for fuel leaks or fuel pressure leaks. Also, perform the same on t\
he fuel line between the com-
mon rail and the injector (See page 11±69, 11±60).
HINT:
Fuel leaks inside the components (Supply pump, etc) may result.
NG REPAIR OR REPLACE
OK

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±557
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0087FUEL RAIL/SYSTEM PRESSURE ± TOO
LOW
DTCP0190FUEL RAIL PRESSURE SENSOR CIRCUIT
DTCP0192FUEL RAIL PRESSURE SENSOR CIRCUIT LOW INPUT
DTCP0193FUEL RAIL PRESSURE SENSOR CIRCUIT HIGH INPUT
HINT:

For more information on the fuel pressure sensor and the common rail system\
, see page 05±517.

If P0087, P0190, P0192 and/or P0193 are present, use the diagnostic troubl\
e code matrix for fuel sys-
tem, see page 05±517.
05CPD±01

A82882
Fuel Pressure
Engine Speed
Normal
Abnormal P0087 Malfunction Detection
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±559
AVENSIS REPAIR MANUAL (RM1018E)
MONITOR DESCRIPTION
P0087 (Fuel pressure sensor output stays at fixed value):
Under normal condition, internal fuel pressure of the common rail usually fluctuates 1 to 2 MPa (10 to 20
kgf/cm
2, 145 to 290 psi) even if the driving condition is constant. The internal fuel pressure is approximately
30 to 40 MPa (306 to 408 kgf/cm
2, 4,351 to 5,801 psi) at idling, and it increases to approx. 50 to 100 MPa
(510 to 1,020 kgf/cm
2, 7,251 to 14,503 psi) when running the engine at 2,500 rpm. This DTC code is set if
there is no fluctuation at the internal fuel pressure.
If this DTC is present, the ECM enters fail±safe mode and limits the engine power. The fail±safe mode will
continue until the ignition switch is turned OFF.
P0190, P0192 and P0193 (Open or short in fuel pressure sensor circuit):
These DTCs are set if the fuel pressure sensor output voltage is out of the standard range. The DTCs stand
for open or short malfunction of the sensor circuit.
If these DTCs are present, the ECM enters fail±safe mode and limits the engine power. The fail±safe mode
will continue until the ignition switch is turned OFF.
MONITOR STRATEGY
P0087:
Required sensorsFuel pressure sensor
Frequency of operationContinuous
Duration1 sec.
CHK ENG operation1 driving cycle
P0190:
Required sensorsFuel pressure sensor
Frequency of operationContinuous
Duration0.5 sec.
CHK ENG operation1 driving cycle
P0192:
Required sensorsFuel pressure sensor
Frequency of operationContinuous
Duration0.5 sec.
CHK ENG operation1 driving cycle

A80452
PCR1E13
ECM Connector
E12PCR2
E2VCS
E2S
VC
A80453
E2
PR2
F16
Wire Harness Side
Fuel Pressure Sensor Connector
VCS
PRE2S
VC
05±562
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
2READ OUTPUT DTC(FUEL PRESSURE SENSOR DTCS ARE OUTPUT AGAIN)
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch ON and push the hand±held tester main switch \
ON.
(c)Select the item ºDIAGNOSIS / OBD/MOBD / DTC INFO / CLEAR CODESº.
(d)Clear the DTCs.
(e)Let the engine idle for 60 seconds and perform quick acceleration to 2,5\
00 rpm for 30 seconds.
(f)Select the item ºDIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODESº.\
(g)Read the DTCs. Result:
Display (DTC output)Proceed to
DTC ºP0087, P0190, P0192 and/or P0193º are output.A
DTC ºP0087, P0190, P0192 and/or P0193º are not output.B
BCHECK FOR INTERMITTENT PROBLEMS (See page 05±528)
A
REPLACE ECM (See page 10±65)
3CHECK HARNESS AND CONNECTOR(FUEL PRESSURE SENSOR ± ECM)
(a)Disconnect the F16 fuel pressure sensor connector.
(b)Disconnect the E12 and E13 ECM connectors.
(c)Check for continuity between the wire harness side con- nector.
Standard (Check for open):
Symbols (Terminal No.)Specified condition
PCR1 (E13±26) ± PR (F16±5)
PCR2 (E13±33) ± PR2 (F16±2)
VCS (E12±2) ± VCS (F16±1)ContinuityVC (E13±18) ± VC (F16±6)Continuity
E2 (E13±28) ± E2 (F16±4)
E2S (E12±1) ± E2S (F16±3)
Standard (Check for short):
Symbols (Terminal No.)Specified condition
PCR1 (E13±26) or PR (F16±5) ± Body ground
PCR2 (E13±33) or PR2 (F16±2) ± Body ground
VCS (E12±2) or VCS (F16±1) ± Body groundNocontinuityVC (E13±18) or VC (F16±6) ± Body groundNo continuity
E2 (E13±28) or E2 (F16±4) ± Body ground
E2S (E12±1) or E2S (F16±3) ± Body ground
NGREPAIR OR REPLACE HARNESS OR CONNECTOR
OK
REPLACE COMMON RAIL ASSY (FUEL PRESSURE SENSOR) (See page 11±78)