AT4657
AT8562
AT3417
OK if hot
Add if hot
AT4252
0 ~ 1 mm (0 ~ 0.04 in.) DI±444
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
679 Author: Date:
(c) Replace the ATF.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF add new fluid through the oil
filler pipe.
Fluid type: ATF D±II or DEXRON®III (DEXRON®II)
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature, 70 ± 80 °C (158 ± 176 °F), and add as
necessary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transaxle.
If there are leaks, it is necessary to repair or replace O±rings,
gasket, oil seals, plugs or other parts.
(e) Inspect and adjust the throttle cable.
(1) Check that the accelerator pedal is fully released.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 ± 1 mm (0 ± 0.04 in.)
If the distance is not the standard, adjust the cable by the ad-
justing nuts.
Q00199
Q04604
Q04700
Bolt Neutral Basic Line
Groove
Bolt
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
DI±445
680 Author: Date:
(f) Inspect and adjust the shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator is not aligned with the correct position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures.
(1) Loosen the nut on the shift lever.
(2) Push the control shaft fully rearward.
(3) Return the control shaft lever 2 notches to N posi-
tion.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, tighten the shift lever nut.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(6) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust the park/neutral position.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.
If it is not as stated above, carry out the following adjustment
procedures.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 5.4 N´m (55 kgf´cm, 48 in´lbf)
For continuity inspection of the park/neutral position
switch, see page DI±479.
(h) Check the idle speed.
Idle speed: 700 ± 50 rpm
(In N position and air conditioner OFF)
6. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operating fluid temperature 50 ± 80 °C (122 ± 176 °F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand±held tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
DI±446
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
681 Author: Date:
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,600 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,600 ± 150 rpm
Evaluation:
ProblemPossible cause
(a) Stall speed low in D and R positions
Engine output may be insufficient
Stator one±way clutch is operating properly
HINT: If more than 600 rpm below the specified value, the torque
converter could be faulty.
(b) Stall speed high in D position
Line pressure too low
Forward clutch slipping
No.2 one±way clutch not operating properly
O/D clutch slipping
(c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
O/D clutch slipping
(d) Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one±way clutch not operating properly
(b) Measure the time lag.
When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch,
and 1st and reverse brake.
NOTICE:
Do the test at normal operating fluid temperature 50 ± 80 °C (122 ± 176 °F).
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value.
(1) Connect an OBD II scan tool or TOYOTA hand±held tester to DLC3.
(2) Fully apply the parking brake.
(3) Start the engine and check idle speed.
Idle speed: 700 ± 50 rpm (In N position and air conditioner OFF)
(4) Shift the shift lever from N to D position. Using a stop watch, measure the time from when the
lever is shifted until the shock is felt.
In the same manner, measure the time lag for N " R.
Time lag:
N " D Less than 1.2 seconds
N " R Less than 1.5 seconds
Evaluation (If N " D time or N " R time lag is longer than specified):
ProblemPossible cause
N " D time lag is longer
Line pressure too low
Forward clutch worn
O/D one±way clutch not operating
N " R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
O/D one±way clutch not operating properly
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
DI±447
682 Author: Date:
7. HYDRAULIC TEST
Measure the line pressure
NOTICE:
Do the test at normal operation fluid temperature 50 ± 80 °C (122 ± 176 °F).
The line pressure test should always be carried out in pairs. One technician should observe
the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST's hose from interfering with the exhaust pipe.
(1) Warm up the ATF.
(2) Remove the test plug on the transaxle case front left side and connect SST.
(See page AX±21 for the location to connect SST)
SST 09992±00095 (09992±00231, 09992±00271)
(3) Fully apply the parking brake and chock the 4 wheels.
(4) Connect an OBD II scan tool or TOYOTA hand±held tester to DLC3.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressed firmly on the brake pedal and shift into D position.
(7) Measure the line pressure when the engine is idling.
(8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when
engine speed reaches stall speed.
(9) In the same manner, do the test in R position.
Specified line pressure:
ConditionD position kPa (kgf/cm2, psi)R position kPa (kgf/cm2, psi)
Idling401 ± 461 (4.1 ± 4.7, 58 ± 66)804 ± 882 (8.2 ± 9.0, 117 ± 128)
Stall1,138 ± 1,236 (11.6 ± 12.6, 165 ± 179)1,716 ± 1,854 (17.5 ± 18.9, 249 ± 269)
If the measured pressure is not up to specified value, recheck the throttle cable adjustment and retest.
Evaluation
ProblemPossible cause
If the measured values at all position are higher
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured values at all position are lower
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective
If pressure is low in the D position onlyD position circuit fluid leakage
Forward clutch defective
If pressure is low in the R position only
R position circuit fluid leakage
Direct clutch defective
1st and reverse brake defective
DI02G±02
Q07932
Engine Coolant Temp. SensorCruise Control ECUThrottle Position Sensor
O/D Main Switch
O/D OFF Indicator LIght
DLC3
DLC2
Stop Light Switch
Vehicle Speed Sensor
Shift Solenoid Valve SLN
Shift Solenoid Valve No.1, No2 Shift Solenoid Valve SL
Park/Neutral Position Switch Direct Clutch Speed SensorECM
Crankshaft Position
Sensor
DI±450
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
685 Author: Date:
PARTS LOCATION
DI1KA±01
FI6810
E10 E9 E8E7
34 33 32 31 30 29 28 2717 18 19 20 21 22 23 24 25 2611 12 13 14 15 161 2 3 4 5 6 7 8 9 101 2 3 4 5 6 7 8
9 10 11 12 13
14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 1 2 3 4
5 6 7
8 9 10 11
12 13 14 15 16 1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17
18 19 20 21 22
ECM Terminals
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
DI±451
686 Author: Date:
TERMINALS OF ECM
Except California, w/ Engine Immobilizer and / or TRAC:
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
IG ON10 ~ 14
S1 e E1 (E10±11 e E8±16)
V e BR1st or 2nd gear10 ~ 14S1 e E1 (E10 11 e E8 16)
V e BR
3rd or O/D gearBelow 1
IG ONBelow 1
S2 e E1 (E10±17 e E8±16)L±B e BR1st or 2nd gear10 ~ 14S2 e E1 (E10 17 e E8 16)LB e BR
3rd or O/D gearBelow 1
SLE1 (E10 27E8 16)PLBRIG ONBelow 1SL e E1 (E10±27 e E8±16)P±L e BRVehicle driving under lock±up position10 ~ 14
NC2+ e NC2± (E9±9 e E9±4)R e GEngine is runningPulse signal is output
Below 1 e 4 ~ 5
SLN+ e SLN±
(E10±2 e E 8±2)W±L e B±YIG ON10 ~ 14
OD1 e E1 (E7±7 e E8±16)Y±B e BRIG ON5 ~ 6
OD2E1 (E7 6E8 16)GOBRO/D main switch ON10 ~ 14OD2 e E1 (E7±6 e E8±16)G±O e BRO/D main switch OFFBelow 1
LE1 (E7 1E8 16)YBRIG ON and Shift lever L position10 ~ 14L e E1 (E7±1 e E8±16)Y e BRIG ON and Shift lever other than L positionBelow 1
2E1 (E7 10E8 16)*1, *3 L±W e BRIG ON and Shift lever 2 position10 ~ 142 e E1 (E7±10 e E8±16)1, 3 LW e BR
*2, *4 O e BRIG ON and Shift lever other than 2 positionBelow 1
RE1 (E7 15E8 16)RBBRIG ON and Shift lever R position10 ~ 14R e E1 (E7±15 e E8±16)R±B e BRIG ON and Shift lever other than R positionBelow 1
NSW e E1BWBRIG ON and Shift lever P or N position10 ~ 14NSW e E1
(E10±14 e E8±16)B±W e BRIG ON and Shift lever other than P or N positionBelow 1
*1: w/ Engine immobilizer system
*2: w/o Engine immobilizer system
*3 TMC made ex. USA w/ TRAC
*4: TMMK made, TMC made USA w/ TRAC
D01054
E10
E9
E8 E11E7
ECM Terminals DI±452
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
687 Author: Date:
California, w/ Engine Immobilizer and / or TRAC:
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
IG ON10 ~ 14
S1 e E1 (E11±7 e E10±17)
V e BR1st or 2nd gear10 ~ 14S1 e E1 (E11 7 e E10 17)
V e BR
3rd or O/D gearBelow 1
IG ONBelow 1
S2 e E1 (E11±8 e E10±17)L±B e BR1st or 2nd gear10 ~ 14S2 e E1 (E11 8 e E10 17)LB e BR
3rd or O/D gearBelow 1
SLE1 (E11 9E10 17)PLBRIG ONBelow 1SL e E1 (E11±9 e E10±17)P±L e BRVehicle driving under lock±up position10 ~ 14
NC2+ e NC2±
(E11±14 e E11±26)R e GEngine is runningPulse signal is output
Below 1 e 4 ~ 5
SLN+ e SLN±
(E11±20 e E11±19)W±L e B±YIG ON10 ~ 14
OD1 e E1 (E8±24 e E10±17)Y±B e BRIG ON5 ~ 6
OD2E1 (E8 10E10 17)GOBRO/D main switch ON10 ~ 14OD2 e E1 (E8±10 e E10±17)G±O e BRO/D main switch OFFBelow 1
LE1 (E8 12E10 17)YBRIG ON and Shift lever L position10 ~ 14L e E1 (E8±12 e E10±17)Y e BRIG ON and Shift lever other than L positionBelow 1
2E1 (E8 3E10 17)*1, *3 L±W e BRIG ON and Shift lever 2 position10 ~ 142 e E1 (E8±3 e E10±17)1, 3 LW e BR
*2, *4 O e BRIG ON and Shift lever other than 2 positionBelow 1
RE1 (E8 2E10 17)RBBRIG ON and Shift lever R position10 ~ 14R e E1 (E8±2 e E10±17)R±B e BRIG ON and Shift lever other than R positionBelow 1
NSW e E1BWBRIG ON and Shift lever P or N position10 ~ 14NSW e E1
(E8±20 e E10±17)B±W e BRIG ON and Shift lever other than P or N positionBelow 1
*1: w/ Engine immobilizer system
*2: w/o Engine immobilizer system
*3 TMC made ex. USA w/ TRAC
*4: TMMK made, TMC made USA w/ TRAC
DI02I±02
± DIAGNOSTICSAUTOMATIC TRANSAXLE (A541E)
DI±453
688 Author: Date:
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
The Matrix Chart is divided into 3 chapters.
Chapter 1: Electronic Circuit Matrix Chart
Chapter 2: On±vehicle Repair Matrix Chart
Chapter 3: Off±vehicle repair Matrix Chart
If the instruction ºProceed to next circuit inspection shown on matrix chartº is given in the flow chart
for each circuit, proceed to the circuit with the next highest number in the table to continue the check.
If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check
and replace the ECM.
1. Chapter 1: Electronic Circuit Matrix Chart
SymptomSuspect AreaSee page
No up±shift (1st " 2nd)ECMIN±31
No up±shift (2nd " 3rd)ECMIN±31
No up±shift (3rd " O/D)
1. O/D main switch circuit
2. O/D cancel signal circuit
3. ECMDI±487
DI±484
IN±31
No down±shift (O/D " 3rd)ECMIN±31
No down±shift (3rd " 2nd)ECMIN±31
No down±shift (2nd " 1st)ECMIN±31
No lock±up or No lock±up offECMIN±31
Shift point too high or too lowECMIN±31
Up±shift to 2nd while in L positionECMIN±31
Up±shift to 3rd while in L positionECMIN±31
Up±shift to O/D from 3rd1. O/D main switch circuit
2. ECMDI±487
IN±31
Up±shift to O/D from 3rd while engine is coldECMIN±31
Harsh engagement (N " D)ECMIN±31
Harsh engagement (Lock±up)ECMIN±31
Harsh engagement (Any driving position)ECMIN±31
Poor accelerationECMIN±31
Large shift shock or engine stalls when starting off or stoppingECMIN±31