2005 TOYOTA AVENSIS clutch

031H2−02
03−14
− SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by−pass pipe No.1 x Cylinder block9.09280 in.
lbf
Water by−pass pipe No. 3 x Cylinder block9.09280 in.
lbf
Oil cooler pipe x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
V−ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Exhaust manifold heat insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Drive plate & ring gear x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub−assy front x Body Bolt
Nut45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133
801,356
81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356
81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No. 2 RH x Transverse engine
engine mounting insulator A
B
52
11 3530
1,15238
83
Vane pump assy x Timing chain cover3737027
Front suspension arm sub−assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub−assy x Frame8.08271 in.
lbf
Radiator reserve tank Sub−assy x Body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf

023N8−01
− PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02−31
AVENSIS Supplement (RM1045E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
09308−00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U151E)
09316−60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U151E)
(09316−00011)Replacer PipeFRONT DIFFERENTIAL OIL
SEAL(U151E)
09350−32014TOYOTA Automatic Transmission
Tool SetAUTOMATIC TRANSAXLE
ASSY(U151E)
(09351−32010)One−way Clutch Test ToolAUTOMATIC TRANSAXLE
ASSY(U151E)
(09351−32020)Stator StopperAUTOMATIC TRANSAXLE
ASSY(U151E)
09520−01010Drive Shaft Remover AttachmentAUTOMATIC TRANSAXLE
ASSY(U151E)
09520−24010Differential Side Gear Shaft
PullerAUTOMATIC TRANSAXLE
ASSY(U151E)
(09520−32040)Shocker SetAUTOMATIC TRANSAXLE
ASSY(U151E)
09628−62011Boll Joint PullerAUTOMATIC TRANSAXLE
ASSY(U151E)
09649−17010Steering Knuckle ToolFRONT DIFFERENTIAL OIL
SEAL(U151E)
09930−00010Drive Shaft Nut ChiselAUTOMATIC TRANSAXLE
ASSY(U151E)

−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
05 −37
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P0420 *3
(05 −1 74)
Catalyst System Efficiency Be-
low Threshold (Bank 1)SGas leakage in exhaust system
S Heated oxygen sensor
S Three −way catalytic converter (inside exhaust manifold)
ff
P0430 *3
(05 −1 74)
Catalyst System Efficiency Be-
low Threshold (Bank 2)SGas leakage in exhaust system
S Heated oxygen sensor
S Three −way catalytic converter (inside exhaust manifold)
ff
P0443
(05 −1 79)Evaporative Emission Control
System Purge Control Valve Cir-
cuitSOpen of short in VSV circuit for EVAP
S VSV for EVAP
S ECM
ff
P0500
(05 −1 83)Vehicle Speed Sensor ”A”
SCombination meter
S Open or short in speed sensor circuit
S Vehicle speed sensor
S ECM
S Skid control ECU
S Clutch or brake slips or gear is broken
ff
P0503
(05 −1 83)Vehicle Speed Sensor ”A”
Intermittent/Erratic/high
SCombination meter
S Open or short in vehicle speed sensor circuit
S Vehicle speed sensor
S ECM
S Skid control ECU
S Clutch or brake slips or gear is broken

f
P0504
(05 −1 85)Brake Switch Correlation
SShort in stop lamp switch signal circuit
S Stop lamp switch
S ECM

f
P0505 *3
(05 −1 89)Idle Air Control System
SElectric throttle control system
S Air induction system
S PCV hose connection
ff
P0555
(05 −1 91)Brake Booster Pressure Sensor
Circuit
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Vacuum hose
S ECM
ff
P0556
(05 −1 94)Brake Booster Pressure Sensor
Circuit Range/Performance
SVacuum hose (between the brake booster and intake manifold,
the brake booster and brake booster pressure sensor, and the
intake manifold and manifold absolute pressure sensor)
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Manifold absolute pressure sensor
S Brake booster
S Open or short in stop lamp switch circuit
S Stop lamp switch
S ECM
ff
P0557
(05 −1 91)Brake Booster Pressure Sensor
Circuit Low Input
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Vacuum hose
S ECM
ff
P0558
(05 −1 91)Brake Booster Pressure Sensor
Circuit High Input
S Open or short in brake booster pressure sensor circuit
S Brake booster pressure sensor
S Vacuum hose
S ECM
ff
P0560
(05 −1 99)System VoltageSOpen in back −up power source circuit
S ECMff
P057 1
(*5)Brake Switch ”A” CircuitS Cruise control system
f
P0604
(05 −202)Internal Control Module Random
Access Memory (RAM) ErrorSECMff
P0606
(05 −202)ECM/PCM ProcessorSECMff

05−38
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P0607
(05 −202)Control Module PerformanceSECMff
P06 17
(05 −203)Starter Relay Circuit High
SShort in Park/Neutral position switch (A/T)
S Park/Neutral position switch (A/T)
S Ignition switch
S ECM
ff
P0657
(05 −202)Actuator Supply Voltage Circuit /
OpenSECMff
P0705 *4
(05 −566)
Transmission Range Sensor Cir-
cuit Malfunction (PRNDL Input)SElectronic controlled automatic transmission (ECT)ff
P07 10*4
(05 −57 1)
Transmission Fluid Temperature
Sensor ”A” circuitS Electronic controlled automatic transmission (ECT)ff
P07 11*3,4
(05 −574)
Transmission Fluid Temperature
Sensor ”A” PerformanceSElectronic controlled automatic transmission (ECT)ff
P07 12*4
(05 −574)
Transmission Fluid Temperature
Sensor ”A” Circuit Low InputSElectronic controlled automatic transmission (ECT)ff
P07 13*4
(05 −574)
Transmission Fluid Temperature
Sensor ”A” Circuit High InputSElectronic controlled automatic transmission (ECT)ff
P07 17*4
(05 −577)
Input/Turbine Speed Sensor ”A”
Circuit No SignalSElectronic controlled automatic transmission (ECT)ff
P0724 *4
(05 −580)Brake Switch ”B” Circuit HighSElectronic controlled automatic transmission (ECT)ff
P074 1*3,4
(05 −582)
Torque Converter Clutch Circuit
Performance or Stuck OffSElectronic controlled automatic transmission (ECT)ff
P0743 *4
(05 −586)
Torque Converter Clutch Circuit
ElectricalSElectronic controlled automatic transmission (ECT)ff
P0746 *3,4
(05 −589)
Pressure Control Solenoid ”A”
Performance (Shift Solenoid
Valve SL 1)
SElectronic controlled automatic transmission (ECT)ff
P0748 *4
(05 −592)
Pressure Control Solenoid ”A”
Electrical (Shift Solenoid Valve
SL 1)
SElectronic controlled automatic transmission (ECT)ff
P0766 *3,4
(05 −595)
Shift Solenoid ”D” Performance
(Shift Solenoid Valve S4)SElectronic controlled automatic transmission (ECT)ff
P077 1*3,4
(05 −598)
Shift Solenoid ”E” Performance
(Shift Solenoid Valve SR)SElectronic controlled automatic transmission (ECT)ff
P0776 *3,4
(05 −60 1)
Pressure Control Solenoid ”B”
Performance (Shift Solenoid
Valve SL2)
S Electronic controlled automatic transmission (ECT)ff
P0778 *4
(05 −604)
Pressure Control Solenoid ”B”
Electrical (Shift Solenoid Valve
SL2)
SElectronic controlled automatic transmission (ECT)ff
P0793 *4
(05 −607)
Intermediate Shaft Speed Sen-
sor ”A” Circuit No SignalSElectronic controlled automatic transmission (ECT)ff
P0796 *3,4
(05 −610)
Pressure Control Solenoid ”C”
performance (Shift Solenoid
Valve SL3)
SElectronic controlled automatic transmission (ECT)ff
P0798 *4
(05 −613)
Pressure Control Solenoid ”C”
Electrical (Shift Solenoid Valve
SL3)
SElectronic controlled automatic transmission (ECT)ff
P0982 *4
(05 −616)Shift Solenoid ”D” Control LowSElectronic controlled automatic transmission (ECT)ff
P0983 *4
(05 −616)Shift Solenoid ”D” Control HighSElectronic controlled automatic transmission (ECT)ff

A81703
From
Speed SensorSkid
Control
ECU4−Pulse
Combination
MeterECM 4−Pulse
A76866
Combination MeterECM
C11V−W
SPD 17
V−W
E10 J/C
18 H
J10
(LHD)J20H
(RHD)H
J10
(LHD)J20H
(RHD)
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
05−183
AVENSIS Supplement (RM1045E)
DTC P0500 VEHICLE SPEED SENSOR ”A”
DTC P0503 VEHICLE SPEED SENSOR ”A”
INTERMITTENT/ERRATIC/HIGH
CIRCUIT DESCRIPTION
The speed sensor detects the wheel speed and sends the appropriate signals to the skid control ECU. The
skid control ECU converts these wheel speed signals into a 4−pulse signal and outputs it to the ECM via
the combination meter. The ECM determines the vehicle speed based on the frequency of these pulse sig-
nals.
DTC No.DTC Detection ConditionTrouble Area
P0500
P0503No vehicle speed sensor signal to ECM under the following
condition (1 trip detection logic):
(a) Vehicle is being driven
SCombination meter
SOpen or short in vehicle speed sensor circuit
SVehicle speed sensor
SECM
SSkid control ECU
SClutch or brake slips or gear is broken
WIRING DIAGRAM
05CJ6−02

05JL5−01
05−536− DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U151E)
AVENSIS Supplement (RM1045E)
MECHANICAL SYSTEM TESTS
1. PERFORM 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:
SPerform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50
to 80˚C(122 to176˚F).
SDo not continuously run this test for longer than10 seconds.
STo ensure safety, do this test in a wide, clear level area which provides good traction.
SThe 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 hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
(7) Quickly read the stall speed at this time.
Stall speed: 2,250á150 rpm
(8) Do the same test in the R position.
Stall speed: 2,250á150 rpm
Evaluation:
ProblemPossible cause
(a) Stall engine speed is low in D and R positions
SEngine power output may be insufficient
SStator one−way clutch not operating properly
HINT: If the value is less than the specified value by 600 rpm or
more, the torque converter could be faulty.
(b) Stall engine speed is high in D position
SLine pressure is too low
SForward clutch slipping
SU/D (Underdrive) brake slipping
SU/D (Underdrive) one−way clutch not operating properly
SNo.1one−way clutch not operating properly
(c) Stall engine speed is high in R position
SLine pressure is too low
SReverse clutch slipping
S1st and reverse brake slipping
SU/D (Underdrive) brake slipping
(d) Stall engine speed is high in D and R positionsSLine pressure is too low
SImproper fluid level

− DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U151E)05−537
AVENSIS Supplement (RM1045E)
(b) Measure the time lag.
(1) 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 direct clutch, forward
clutch, and1st and reverse brake.
NOTICE:
SPerform the test at the normal operating ATF temperature 50 to 80˚C(122 to176˚F).
SBe sure to allow1minute interval between tests.
SPerform the test three times, and measure the time lags. Calculate the average value of the three
time lags.
(2) Connect an hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Start and warm up the engine and check idle speed.
Idle speed: approx. 700 rpm (In N position and A/C OFF)
(5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever
is shifted until the shock is felt.
Time lag: N
D less than1.2 seconds
(6) In the same way, measure the time lag for N
R.
Time lag: N
R less than1.5 seconds
Evaluation (If N
DorN
R time lag is longer than the specified):
ProblemPossible cause
N
D time lag is longer
SLine pressure is too low
SForward clutch worn
SNo.1one−way clutch not operating properly
SU/D (Underdrive) one−way clutch not operating
SU/D (Underdrive) brake worn
N
R time lag is longer
SLine pressure is too low
SReverse clutch worn
S1st and reverse brake worn
SU/D (Underdrive) brake worn

05JL4−01
05 −534−
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U 151E)
AVENSIS Supplement (RM 1045E)
ROAD TEST
1. PROBLEM SYMPTOM CONFIRMATION
(a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem
is that the transaxle does not shift up, shift down, or the shift point is too high or too low, conduct the
following road test referring to the automatic shift schedule and simulate the problem symptoms.
2. ROAD TEST
NOTICE:
Perform the test at the ATF (Automatic Transmission Fluid) temperature 50 to 80 ˚C( 122 to 176 ˚F) in
the normal operation.
(a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points.
(1 ) Check up −shift operation.
Check that 1
2, 2
3, 3
4 and 4
5th up −shifts take place, and that the shift points conform
to the automatic shift schedule (see page 03 −33).
HINT:
5th Gear Up −shift Prohibition Control
S ATF temperature is −2 ˚C (28 ˚F ) or less.
5th and 4th Gear Lock −up Prohibition Control
S Brake pedal is depressed.
S Accelerator pedal is released.
S Engine coolant temperature is 60 ˚C( 140 ˚F) or less.
(2) Check for shift shock and slip. Check for shock and slip at the 1
2, 2
3, 3
4 and 4
5th up −shifts.
(3) Check for abnormal noise and vibration. Check for abnormal noise and vibration when up −shifting from 1
2, 2
3, 3
4 and 4
5
while driving with the shift lever in the D position, and check while driving in the lock −up condition.
HINT:
The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due
to loss of balance in the differential, torque converter clutch, etc.
(4) Check kick −down operation.
Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick −downs take
place while driving with the shift lever in the D position. Confirm that each speed is within the
applicable vehicle speed range indicated in the automatic shift schedule (see page 03 −33).
(5) Check for abnormal shock and slip at kick −down.
(6) Check the lock −up mechanism.
SDrive in D position (5th gear), at a steady speed (lock −up ON).
SLightly depress the accelerator pedal and check that the engine speed does not change
abruptly.
HINT:
SThere is no lock −up function in the 1st, 2nd and 3rd gear.
S4th lock −up operates while uphill −downhill control is active in the D position.
SIf there is a big jump in engine speed, there is no lock −up.