80 AVENSIS – NEW FEATURES

8. Engine Control System

General
Along with the adoption of the D-CAT, the following controls have been added:

" System Comparison List A

With Without
System Outline
D-CAT D-CAT
Based on the signals received from the sensors, the engine ECU
Fuel Injection
determines the fuel injection volume in accordance with the engine f f
Volume Control
condition.
Based on the signals received from the sensors, the engine ECU
Fuel Injection
determines the fuel injection timing in accordance with the engine f f
Timing Control
condition.
DPNR Catalyst
Support Control Adds fuel into the exhaust gas in order to reduce PM and NOx. f —
(See page 90)
Based on the signals received from the sensors, the engine ECU
Fuel Pressure
determines the fuel pressure via SCV (Suction Control Valve) and f f
Control
pressure discharge valve in accordance with the engine condition.
Based on the signals received from the sensors, the engine ECU
Pilot Injection
determines pilot injection volume/timing, and interval (between pilot f f
Control
injection and main injection) in accordance with the engine condition.
The engine ECU determines the idle speed in accordance with the
Idle Speed
engine condition, and controls the fuel injection volume in order to f f
Control
maintain the target idle speed.
Glow Plug Controls the length of time when the current is applied to the glow
f f
Control plugs, in accordance with engine coolant temperature.
Based on the signals received from the sensors, the engine ECU
EGR Control determines the EGR volume via EGR valve and intake restrictor valve f f
in accordance with the engine condition.
Turbo Pressure Based on the signals received from the sensors, the engine ECU controls
f f
Control the actuator via VRV in accordance with the engine condition.
Intake Restrictor Fully close the intake restrictor valve in order to reduce the vibration
f f
Valve Control when the engine is stopped.
Air Conditioner By controlling the air conditioner compressor ON or OFF in
f f
Cut-off Control accordance with the engine condition, drivability is maintained.
Engine Prohibits fuel injection if an attempt is made to start the engine with
f f
Immobilizer an invalid ignition key.
Diagnosis When the engine ECU detects a malfunction, the engine ECU
f f
(See page 91) di agnoses and memorizes the failed section.
When the engine ECU detects a malfunction, the engine ECU stops or
Fail-Safe f f
controls the engine according to the data already stored in the memory.
 AVENSIS – NEW FEATURES 81

Construction
The configuration of the engine control system is as shown in the following chart.

: New

SENSORS ACTUATOR
VG #10
AIR FLOW METER No.1 INJECTOR
#20
ATMOSPHERIC TEMP. SENSOR
THA No.2 INJECTOR 3
#30
THIA EDU No.3 INJECTOR
INTAKE AIR TEMP. SENSOR #40
No.4 INJECTOR
THW INJF
WATER TEMP. SENSOR
PRD PRESSURE DISCHARGE
PIM VALVE
TURBO PRESSURE SENSOR

CRANKSHAFT POSITION NE FIV EXHAUST FUEL ADDITION

SENSOR INJECTOR

CAMSHAFT POSITION G
SENSOR PCV±
SUCTION CONTROL VALVE
THF
FUEL TEMP. SENSOR
VCPA IREL
VCP2
EDU RELAY
ACCELERATOR PEDAL
POSITION SENSOR VPA
VPA2
THROTTLE POSITION THOP DIESEL THROTTLE
SWITCH Engine CONTROL
ECU
DISEL THROTTLE VLU LUSL
PODITION SENSOR Rotary Solenoid

AF2+
AIR FUEL RATIO SENSOR
ME2+ EGR CONTROL
AIR FUEL RATIO SENSOR
HEATER EGRS
HAF2 EGR VALVE (Linear Motor)
COMBINATION METER
SPD
D Vehicle Speed Signal
TACH GLOW PLUG CONTROL
IGNITION SWITCH GREL
STA GLOW PLUG RELAY
D Starter Signal IGSW
D Ignition Signal
PCR1
PCR2 TURBOCHARGER
FUEL PRESSURE SENSOR VCS CONTROL
SSW VN
DCAT SWITCH Vacuum Regulating Valve

(Continued)

258AE35
82 AVENSIS – NEW FEATURES

DIFFERENTIAL PRESSURE PEX

SENSOR FAN
COOLING FAN RELAY
EGR VALVE POSITION EGLS
SENSOR

EXHAUST GAS TEMPERATURE THCO

SENSOR (ON DOWN STREAM)

EXHAUST GAS TEMPERATURE THCI

SENSOR (ON UP STREAM) Engine
ECU CCS
DF CRUISE CONTROL SWITCH
ALTERNATOR
RL
PTC1
MPX1
AIR CONDITIONER AMPLIFIER MPX2

BEAN
D
CLUTCH START SWITCH
IMO MREL
TRANSPONDER KEY MAIN RELAY
IMI
STP
STOP LIGHT SWITCH
TRC±
SKID CONTRL ECU NEO Atmospheric
ENG± Pressure
TC
Sensor
SIL
DLC 3
WFSE
W CHECK ENGINE
CLSW
CLUTCH SWITCH WARNING LIGHT

+B BATT

MAIN RELAY BATTERY

258AE36
 AVENSIS – NEW FEATURES 83

Engine Control System Diagram

Accelerator Pedal SCV Supply Pump

Position Sensor

BEAN Fuel Pressure

Sensor
Air Conditioner
Amplifier Fuel Temp. Fuel Pressure

Ignition Switch Signal

Sensor Discharge Valve 3
Starter Signal
DCAT Switch Common-Rail
Vehicle Speed Signal
Alternator
DLC3
Engine EDU Relay
ECU
EDU

Air Fuel Ratio Sensor Heater

Atmospheric
Pressure Intake Air
Sensor Temp. Sensor
Diesel Throttle
Atmospheric Position Sensor
Temp. Sensor

EGR Valve
Air Flow Meter Main
Injector

Actuator Camshaft
Position Turbo
Sensor Pressure
E-VRV Sensor
Glow
Exhaust Temp. Sensor (UP) Exhaust Fuel Plug
Addition
Water Temp.
Exhaust Temp. Sensor (DOWN) Injector
Sensor
Differential
Glow
Pressure sensor
Relay

Crankshaft
Air Fuel Ratio Sensor Position
Sensor

258AE37
84 AVENSIS – NEW FEATURES

Layout of Main Components

Air Flow Meter

EDU

Glow Plug
Camshaft Position
Sensor Injector

Exhaust Temp. Pressure Discharge Valve

Sensor (UP) Exhaut Fuel Addition Injector Air Fuel Ratio Sensor

Fuel Pressure Intake Air Temp. Sensor

Sensor
Glow Plug Indicator

Differential EGR Valve

Pressure Sensor
Turbo Pressure Check Engine
Sensor Warning Light

Exhaust
Temp. Diesel Throttle
DCAT Switch
Sensor Position Sensor
(DOWN) Water Temp. Sensor
E-VRV

SCV

Engine ECU
Supply Pump Fuel Temp. Sensor
Accelerator Pedal
DLC3 Position Sensor
Clutch Start
Switch

258AE38
 AVENSIS – NEW FEATURES 85

Main Components of Engine Control System

1) General
The main components of the 1CD-FTV engine With D-CAT control system are as follows:
: New
Quantity
Components Outline Without
With D-CAT
D-CAT
3
Engine ECU 32-bit 1 z
Air Flow Meter Hot- wire Type 1 z
Crankshaft Position Sensor
Pick-up Coil Type (36-2) 1 z
(Rotor Teeth)
Camshaft Position Sensor
Pick-up Coil Type (1) 1 z
(Rotor Teeth)
Accelerator Pedal Position Sensor Linear Type 2 (Main, Sub) z
Semiconductor Strain
Fuel Pressure Sensor 1 z
Gauge Type (Two Circuits)
EDU DC/ DC Converter 1 z
Semiconductor Strain
Differential Pressure Sensor 1 —
Gauge Type
Exhaust Gas Temperature Sensor
Thermister Type 2 —
(UP, DOWN)
Air Fuel Ratio Sensor Type with Heater (Cup Type) 1 —
EGR Valve Position Sensor Contact point type 1 —
Diesel Throttle Position Sensor Non-contact point type 1 —
DCAT Switch
DCAT Switch For switching to fuel with 1 —
sulphur content
86 AVENSIS – NEW FEATURES

2) Differential Pressure Sensor

D The differential pressure sensor measures the pressure differences between front and back of the
DPNR catalyst with PM in order to detect the clogging.
D The sensor is mounted on the side of the vehicle, where the effects of vibration are minimal. The DPNR
catalyst and the sensor are connected with pipes.

Differential Pressure
Sensor

258AE50

Vp (V)
258AE39

4.65
Voltage

0.75

0 Pressure (kPa) 100

258AE49
 AVENSIS – NEW FEATURES 87

3) Exhaust Gas Temp. Sensor

The exhaust gas temperature sensor, which is a thermister type, is installed in front and back of the DPNR
catalyst, in order to detect the temperature of the catalyst.

106

Electric Resistance Value ( Ω )

105
3
104

103

102
Exhaust Gas Temp. Sensor 0 100 200 300 400 500 600 700 800 900
258AE40
Exhaust Gas Temperature (_C)
258AE41

4) Air Fuel Ratio Sensor

This sensor is based on a sensor that has been developed for gasoline engines. Its cover has been changed
for diesel engine applications in order to eliminate the influences of the sensor temperature and the PM.
This sensor, which is mounted after the DPNR catalyst, detects the air-fuel ratio after the gases have been
reduced.

(V)
4.2
Air Fuel Ratio Sensor
(Output)

2.2
Element
Heater
Rich Lean
Air Fuel Ratio Sensor
258EG59 258AE55
88 AVENSIS – NEW FEATURES

5) EGR Position Sensor

EGR Position Sensor detects the amount of lift of the EGR valve and sends the corresponding signal to
the engine ECU.

Brush

Coil Spring

Connector
Terminal

Leaf Spring

EGR Position Sensor Shaft

258AE52

(V)

5
Output Voltage

0
Sensor Stroke
258AE53
 AVENSIS – NEW FEATURES 89

6) Diesel Throttle Position Sensor

The Diesel throttle position sensor is mounted on the throttle body, to detect the opening angle of the
throttle valve, the throttle position sensor converts the magnetic flux density that changes when the
magnetic yoke (located on the same axis as the throttle shaft) rotates around the hall IC into electric
signals to operate the throttle control motor.

Hall IC [V]
(for Diesel Throttle
Position Sensor) 5
3

Output Voltage
0
0 100
Magnet Throttle Throttle Position Ratio [%]
Valve
258AE62 258AE61

7) DCAT Switch
The ability of this system is brought into full play through the use of low-sulphur diesel fuel. If
high-sulphur diesel fuel must be used temporarily because low-sulphur diesel fuel is unavailable, the
driver can turn this switch ON to minimize damage to the DPNR catalyst.
*: The map below shows the countries in which low-sulphur diesel fuel is available (as of September
2003).

: Low-sulphur diesel fuel

: High-sulphur diesel fuel

Fuel Availability Map 258AE64

90 AVENSIS – NEW FEATURES

DPNR Catalyst Support Control

1) General
The DPNR catalyst support control is divided into the following: during NOx storage, NOx reduction,
PM reclaiming control, and sulphur poison recovery control.

Air-fuel ratio
Main reduction Main storage
DPNR catalyst support control control of
substances substances
exhaust gas
During NOx storage Lean PM, HC, CO NOx, SOx
During NOx reduction Rich NOx, PM, HC, CO SOx
During PM reclaiming control Lean PM —
During sulphur poison recovery
Rich/ Lean SOx —
control

2) During NOx storage

D Normally, the air-fuel ratio of the diesel engine is in the lean state, and the NOx becomes stored in the
NOx storage material in the form of nitrate (NO2).
D The active oxygen (O) that is created at that time oxidizes the PM. Thereafter, the excess oxygen from
the surrounding area oxidizes the PM at once, which becomes discharged in the form of CO2.

3) During NOx Reduction

D The air-fuel ratio of the exhaust gas is enriched momentarily by the EGR and the exhaust fuel addition.
As a result, NO and a large amount of oxygen are created in the DPNR catalyst, and when the HC and
CO in the exhaust gas increase, the NO becomes reduced to N2 by HC and CO.
D At this time, the large amount of active oxygen that is created in the catalyst promotes the oxidation
of the PM, which is discharged in the form of CO2.

Lean Rich

H2O
NO HC N2 CO2
O2 NO2+O* CO NO+O*
Pt Pt
NOx
Filter base material Filter base material
NOx
During NOx storage During NOx
Storage material reduction
CO2
PM CO2
NO+O2 PM
O*
PM NO2 O* O*
Pt Pt
Filter base material Filter base material

258AE23
 AVENSIS – NEW FEATURES 91

Diagnosis

1) General
D The diagnosis system of the 1CD-FTV with D-CAT engine uses the EURO-OBD (Europe On-Board
Diagnosis) that complies with European regulations.
D When the Engine ECU detects a malfunction, the Engine ECU makes a diagnosis and memorizes the
failed section. Furthermore, the check engine warning light in the combination meter illuminates to
inform the driver.
D At the same time, the DTCs (Diagnostic Trouble Codes) are stored in memory. The DTCs can be read 3
by connecting a hand-held tester.
D The DTCs have been further divided to correspond to SAE codes.
D Along with the addition of the D-CAT, DTCs (Diagnostic Trouble Codes) have been added.
D For details, see the Avensis Repair Manual (Pub. No. RM1045E).
92 AVENSIS – NEW FEATURES

Fail-Safe
When the Engine ECU detects a malfunction, the Engine ECU stops or controls the engine according to the
data already stored in the memory as the following conditions.

" Fail-Safe Control List A

: New
DTC Fail-safe Operation Fail-safe Deactivation Conditions
P0087 VTA is fixed at 10 % IG OFF
P0088 VTA is fixed at 10 %. IG OFF
After fail-safe driving control is performed
P0093 IG OFF
for 1 minute, engine stalls.
P0095, P0097, Intake air temperature is fixed at 150_C
Returned to normal condition
P0098 (302_F).
P0105, P0107,
Turbo pressure is set at fixed value. Returned to normal condition
P0108
When fuel temp. sensor operates normal and
intake air temp. is less than 15_C (59_F),
value of fuel temp. sensor is substituted.
P0115, P0117, When fuel temp. sensor operates normal and
Returned to normal condition
P0118 intake air temp. is more than 20_C (68_F),
value is fixed at 110_C (230_F).
When the fuel temp. sensor is abnormal,
value is fixed at 40_C (104_F).
P0168 Out put limit Returned to normal condition
P0180, P0182,
Fuel temperature is fixed at 40_C (104.0_F). Returned to normal condition
P0183
P0190, P0191,
VTA is fixed at 10 %. IG OFF
P0192, P0193
P0120, P0122, Open circuit in diesel throttle position sensor
IG OFF
P0123 Accelerator opening limit at 30%
P0200 VTA is fixed at 25 %. IG OFF
P0335 Out put limit Returned to normal condition
P048 VTA is fixed at 25 %. IG OFF
Open circuit in EGR position sensor
P0405, P0406 IG OFF
Accelerator opening limit at 30%
P0500 Vehicle speed is fixed at 0 km / h (0 mph). Vehicle speed y 10 km / h (6 mph)
P1229 VTA is fixed at 10 %. IG OFF
P1271 VTA is fixed at 25 %. IG OFF
P1272 VTA is fixed at 25 %. IG OFF
P1425, P1427 Open
p circuit in differential ppressure sensor
—
P1428 No operation occurs
P2120, P2122,
P2123, P2125,
Out put limit +B OFF
P2127, P2128,
P2138
P0544, P0545,
Open circuit in exhaust gas temperature sensor
P0546, P2031, IG OFF
Accelerator opening limit at 30%
P2032, P2033
Open circuit in exhaust fuel addition injector
P2047 IG OFF
Accelerator opening limit at 30%