Page 4897 of 5135

D03561
D03560
B
A
D03904
O−ring
B−3 Accumulator Piston
D25512
AT F
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−67
U151E, U151F A/T REPAIR MANUAL (RM1021U)
138. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgfcm,15ftlbf)
Bolt length: 25 mm (0.984 in.)
NOTICE:
Be sure the parking rod is placed between the parking pawl
and the guide of the parking bracket when the parking
bracket is assembled.
139. INSTALL MANUAL DETENT SPRING SUB−ASSY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring and cover in
this order.
HINT:
Tighten them in the order, A and B.
Torque:
Bolt A: 20 Nm (205 kgfcm,15ftlbf)
Bolt B:12Nm(120 kgfcm, 9 ftlbf)
Bolt length:
Bolt A: 27 mm (1.063 in.)
Bolt B:16 mm (0.630 in.)
140. INSTALL B−3 ACCUMULATOR PISTON
(a) Coat a new O−ring with ATF, install it to the B−3 accumula-
tor piston.
NOTICE:
Install the O−ring to the accumulator piston and the accu-
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
Inner 62.00 (2.4409) /
15.50 (0.610)Purple
Outer 74.23 (2.9224) /
21.70 (0.854)Purple
Page 4898 of 5135

D26402
O−ring
O−ring Reverse clutch Accumulator Piston
C92978
AT F
D03902
O−ring
C−3 Accumulator Piston
C83146
D03555
40−68
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
141. INSTALL REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Coat the 2 new O−rings with ATF, install them to the re-
verse accumulator piston.
NOTICE:
Install the O−ring to the accumulator piston and the accu-
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
60.96 (2.3999) /
14.10 (0.555)Yellow
142. INSTALL C−3 ACCUMULATOR PISTON
(a) Coat a new O−ring with ATF, install it to the C−3 accumu-
lator piston.
NOTICE:
Install the O−ring to the accumulator piston and the accu-
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
72.20 (2.8425) /
19.0 (0.748)Colorless
(c) Install the spring from the C−3 accumulator piston.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Page 4899 of 5135

D03554
Check Ball
C83129
C83128
C83127
D03636AT F
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−69
U151E, U151F A/T REPAIR MANUAL (RM1021U)
143. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Regarding the installation of the spring for the check ball
body, be sure to place the spring in the hole in the ball body.
Be careful about the parts orientation.
144. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to the
transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
145. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF,
install it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
146. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No. 1 with ATF, install
it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
147. INSTALL TRANSMISSION WIRE
(a) Coat a new O−ring with ATF, install it to the transmission
wire.
NOTICE:
Be careful about the O−ring not to have a twist, a protrusion
and a pinching during installing the wire transmission to
the transaxle case. Moreover, apply enough ATF to the O−
ring prior to assembling.
Page 4900 of 5135

D03547
Transmission Wire
C91927
GFE
A
B
C
D
C91933
A
CB
B
A
C
L
L
C91932
O−ring
40−70
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the transmission wire retaining bolt.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
148. CONNECT TRANSMISSION WIRE
(a) Coat a O−ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor, with the lock plate and
bolt.
Torque: 6.6 Nm (67 kgfcm, 58 in.lbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
SConnect the connector to A, B, C, D, E, F, G, from
shorter one.
SApply ATF to the bolt.
149. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the
valve body with 17 bolts to the transaxle case.
Torque:11Nm(110 kgfcm, 8 ftlbf)
Bolt length:
Bolt A: 41mm (1.614 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 25 mm (0.984 in.)
NOTICE:
SPush the valve body against the accumulator piston
spring and the check ball body to install it.
SWhen installing the valve body to the transaxle case,
do not hold the solenoids.
STighten temporarily those bolts marked byLin the il-
lustration first because they are positioning bolts.
150. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O−ring with ATF, install it to the oil strainer.
NOTICE:
Assemble the O−ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O−ring prior
to assembling.
Page 4901 of 5135

C91931
Valve Body Oil
Strainer Assy.
C86316
Magnet
C91925
D26716
D03900D30672
Speed Sensor
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−71
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the oil strainer and 3 bolts to the valve body.
Torque:11Nm(110 kgfcm, 8 ftlbf)
NOTICE:
Apply ATF to the bolts.
151. INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install the new oil pan gasket with the 18 bolts to the trans-
axle case.
Torque: 7.8 Nm (80 kgfcm, 69 in.lbf)
NOTICE:
SBecause the bolts should be seal bolts, apply seal
packing to new bolts and tighten them within10 min-
utes after application.
SRemove any oil or grease from the contacting surface
of the transaxle case and the oil pan with the gasket
completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO.1PLUG
(a) Coat the 4 new O−rings with ATF, install them to the 4
transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
153. INSTALL SPEED SENSOR
(a) Install them to the 2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Torque:11.0 Nm(115 kgfcm, 8 ftlbf)
Page 4902 of 5135
C83144
Elbow
O−ring
C83143
Union
O−ring
D09639
D09640Control Shaft Lever
40−72
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Coat a new O−ring with ATF, install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 Nm (276 kgfcm, 20 ftlbf)
155. INSTALL OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Coat a new O−ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 25 Nm (255 kgfcm,18ftlbf)
156. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose into the transaxle case certainly.
157. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch onto the manual
valve lever shaft and temporarily install the 2 adjusting
bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 Nm (70 kgfcm, 61in.lbf)
(c) Temporarily install control shaft lever.
Page 4903 of 5135
D09641
D09642
D09643
D09644
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−73
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Turn the lever counterclockwise until it stops, and then
turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
(h) Using a screwdriver, stake the nut with the nut stopper.
(i) Install the control shaft lever, washer and nut.
Torque:13Nm(130 kgfcm, 9 ftlbf)
158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB−ASSY
(a) Coat a new O−ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub−assy to the transaxle assy.
Torque: 6.9 Nm (70 kgfcm, 61ftlbf)
Page 4904 of 5135

05JOB–03
– DIAGNOSTICSSFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–21
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
FAIL–SAFE CHART
If any of the following DTCs are recorded, the ECM enters fail–safe mode.
DTC No.Fail–Safe OperationFail–Safe Deactivation Condition
P0031
P0032Heated oxygen sensor (Sensor 1) heater is turned offIgnition switch turned to OFF
P0037
P0038Heated oxygen sensor (Sensor 2) heater is turned offIgnition switch turned to OFF
P0100
P0102
P0103Ignition timing is calculated from engine RPM and Throttle
Position (TP)”Pass” condition detected
P0110
P0112
P0113
Intake Air Temperature (IAT) is fixed at 20C (68F)”Pass” condition detected
P0115
P0117
P0118
Engine Coolant Temperature (ECT) is fixed at 80 ”Pass” condition detected
P0120
P0122
P0123
P0220
P0222
P0223
P2102
P2103
P2111
P2112
P2118
P2119
P2135
When Electronic Throttle Control System (ETCS) is mal-
functioning, electric current to throttle actuator is cut off and
throttle valve returns to throttle position (TP) 16 by its
spring.
Then, required engine power is calculated using ignition
timing and Accelerator Pedal Position (APP). Engine is
controlled by intermittent fuel–cut.
As a result, fully slowly depressing accelerator pedal en-
ables driving at minimum speed. However, quickly depress-
ing pedal would vary vehicle speed remarkably.
”Pass” condition detected followed by the ignition switch
turned to OFF
P0121Fuel is cut intermittently”Pass” condition detected followed by the ignition switch
turned to OFF
P0325
P0327
P0328
Maximum ignition timing retardationIgnition switch turned to OFF
P0351
P0352
P0353
P0354
Fuel is cut”Pass” condition detected
P2120
P2121
P2122
P2123
P2125
P2127
P2128
P2138
Accelerator Pedal Position (APP) sensor has main circuit
and associate circuit. When one of circuits is malfunction-
ing, APP is calculated by output of other circuit. When both
of circuits are malfunctioning, it is interpreted that accelera-
tor pedal is releasing. As a result, throttle valve is closed
and engine idles.
”Pass” condition detected followed by the ignition switch
turned to OFF