2005 TOYOTA AVENSIS manual transmission

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)

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.

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)

–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–31
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)DTC No.
(See Page) Memory
*1
MIL
Trouble Area
Detection Item
P0607
( 05–170 )Control Module PerformanceECM
P0617
( 05–171 )Starter Relay Circuit High
Short in park/neutral position switch circuit (MMT)
 Short in STA circuit
 Park/neutral position switch (MMT)
 ECM

P0657
( 05–170 )Actuator Supply Voltage Circuit /
OpenECM
P0705
( 05–247 )Transmission Range Sensor Cir-
cuit Malfunction (PRNDL Input)Electronic control automatic transaxle
P0710
( 05–252 )Transmission Fluid Temperature
Sensor ”A” CircuitElectronic control automatic transaxle
P0711
( 05–255 )Transmission Fluid Temperature
Sensor ”A” PerformanceElectronic control automatic transaxle
P0712
( 05–252 )Transmission Fluid Temperature
Sensor ”A” Circuit Low InputElectronic control automatic transaxle
P0713
( 05–252 )Transmission Fluid Temperature
Sensor ”A” Circuit High InputElectronic control automatic transaxle
P0717
( 05–258 )Turbine Speed Sensor Circuit No
SignalElectronic control automatic transaxle
P0724
( 05–261 )Brake Switch ”B” Circuit HighElectronic control automatic transaxle
P0741
( 05–264 )Torque Converter Clutch Sole-
noid Performance (Shift Solenoid
Valve SL)
Electronic control automatic transaxle
P0751
( 05–268 )Shift Solenoid ”A” Performance
(Shift Solenoid Valve S1)Electronic control automatic transaxle
P0756
( 05–271 )Shift Solenoid ”B” Performance
(Shift Solenoid Valve S2)Electronic control automatic transaxle
P0787
( 05–274 )Shift/Timing Solenoid Low (Shift
Solenoid Valve ST) Electronic control automatic transaxle
P0788
( 05–274 )Shift/Timing Solenoid High (Shift
Solenoid Valve ST)Electronic control automatic transaxle
P0973
( 05–277 )Shift Solenoid ”A” Control Circuit
Low (Shift Solenoid Valve S1)Electronic control automatic transaxle
P0974
( 05–277 )Shift Solenoid ”A” Control Circuit
High (Shift Solenoid Valve S1)Electronic control automatic transaxle
P0976
( 05–280 )Shift Solenoid ”B” Control Circuit
Low (Shift Solenoid Valve S2)Electronic control automatic transaxle
P0977
( 05–280 )Shift Solenoid ”B” Control Circuit
High (Shift Solenoid Valve S2)Electronic control automatic transaxle
P0998
( 05–283 )Shift Solenoid ”F” Control Circuit
Low (Shift Solenoid Valve SB)Electronic control automatic transaxle
P0999
( 05–283 )Shift Solenoid ”F” Control Circuit
High (Shift Solenoid Valve SB)Electronic control automatic transaxle
P2102
( 05–174 )Throttle Actuator Control Motor
Circuit LowOpen in throttle control actuator circuit
 Throttle actuator
 ECM

P2103
( 05–174 )Throttle Actuator Control Motor
Circuit High
Short in throttle control actuator circuit
 Throttle actuator
 Throttle valve
 Throttle body assembly
 ECM


A18294
SPD (+)
E1 (–)
E10
ECM Connector
E13
A62954
Turn Wheel
4.5
to 5.5V
0V
05–160
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
2 READ VALUE OF INTELLIGENT TESTER II(VEHICLE SPEED)
(a) Connect the intelligent tester ll to the DLC3.
(b) Start the engine and turn the intelligent tester ll ON.
(c) On the intelligent tester ll, select the following menu items: Powertrai\
n / Engine and ECT / Data List / Vehicle SPD.
(d) Check the vehicle speed at the engine speed of 2,000 rpm or more when th\
e vehicle is running. Standard: Same value as the actual vehicle speed.
YES CHECK FOR INTERMITTENT PROBLEMS (See page 05–9 )
NO
3 INSPECT ECM(SPD VOLTAGE)
(a) Shift the transmission gear selector lever to the neutral position.
(b) Jack up the vehicle.
(c) Turn the ignition switch to ON.
(d) Measure the voltage between the terminals of the E10
and E13 ECM connectors as the wheel is turned slowly.
Standard:
Tester ConnectionSpecified Condition
SPD (E10–17) – E1 (E13–5)Generated intermittently
HINT:
The output voltage should fluctuate up and down similarly to the
diagram on the left when the wheel is turned slowly.
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
REPLACE ECM (See page 10–65 of Pub. No. RM1018E AVENSIS)

056IK–10
–
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)05–245
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DIAGNOSTIC TROUBLE CODE CHART
If a DTC is displayed during the DTC check, check the parts listed in the \
table below and proceed to the page
given.
HINT:

*1 :  ... MIL (Malfunction Indicator Lamp) light up

*2 : ’’ ’’ mark means ECM memorizes the malfunction code if the ECM detects the DT\
C detection
condition.

This DTC may be output when the clutch, brake and gear components etc. inside\
the automatic trans-
axle are damaged.
DTC No.
(See Page)Detection ItemTrouble AreaMIL *1Memory *2
P0500
( 05–158 )Vehicle Speed Sensor ”A”

Combination meter

Open or short in vehicle speed sensor circuit

Vehicle speed sensor

ECM

P0705
( 05–247 )Transmission Range Sensor Cir-
cuit Malfunction (PRNDL Input)
Open or short in park/neutral position switch circuit

Park/neutral position switch

ECM

P0710
( 05–252 )Transmission Fluid Temperature
Sensor ”A” Circuit
Open or short in ATF temperature sensor circuit

Transmission wire (ATF temperature sensor)

ECM

P0711
( 05–255 )Transmission Fluid Temperature
Sensor ”A” Performance
Open or short in ATF temperature sensor circuit

Transmission wire (ATF temperature sensor)

ECM

P0712
( 05–252 )Transmission Fluid Temperature
Sensor ”A” Circuit Low Input
Short in ATF temperature sensor circuit

Transmission wire (ATF temperature sensor)

ECM

P0713
( 05–252 )Transmission Fluid Temperature
Sensor ”A” Circuit High Input
Open in ATF temperature sensor circuit

Transmission wire (ATF temperature sensor)

ECM

P0717
( 05–258 )Turbine Speed Sensor Circuit No
Signal

Open or short in transmission revolution sensor NT (speed
sensor NT) circuit

Transmission revolution sensor NT (speed sensor NT)

ECM

Automatic transaxle assembly

P0724
( 05–261 )Brake Switch ”B” Circuit High

Short in stop light switch circuit

Stop light switch

ECM

P0741
( 05–264 )Torque Converter Clutch Sole-
noid Performance
(Shift Solenoid Valve SL)

Shift solenoid valve SL remains open or closed

Valve body is blocked

Shift solenoid valve SL

Torque converter clutch

Automatic transaxle (clutch, brake or gear etc.)

Line pressure is too low

ECM

P0751
( 05–268 )Shift Solenoid ”A” Performance
(Shift Solenoid Valve S1)

Shift solenoid valve S1 remains open or closed

Valve body is blocked

Shift solenoid valve S1

Automatic transaxle (clutch, brake or gear etc.)

ECM

P0756
( 05–271 )Shift Solenoid ”B” Performance
(Shift Solenoid Valve S2)

Shift solenoid valve S2 remains open or closed

Valve body is blocked

Shift solenoid valve S2

Automatic transaxle (clutch, brake or gear etc.)

ECM


05KAQ–02
G24063
SST
SST
– DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)05–223
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
HYDRAULIC TEST
1. PERFORM HYDRAULIC TEST
(a) Measure the line pressure.
NOTICE:

Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50
to 80
C (122 to 176
F).

The line pressure test should always be carried out in pairs. One technician should observe
the conditions of wheels or wheel stopper outside the vehicle while the other is doing the test.

Be careful to prevent SST’s hose from interfering with the exhaust pipe.

This check must be conducted after checking and adjusting engine.

Perform under condition that A/C is OFF.

When conducting stall test, do not continue more than 10 seconds.
(1) Warm up the ATF.
(2) Remove the test plug on the left side of the trans-
axle case and connect SST.
SST 09992–00095 (09992– 00231, 09992–00271)
(3) Fully apply the parking brake and chock the 4
wheels.
(4) Connect an Intelligent Tester II to the DLC3.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressing firmly on the brake ped-
al 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 way, do the test in R position.
Specified line pressure:
ConditionD position kPa (kgf / cm2, psi)R position kPa (kgf / cm2, psi)
Idling372 to 412 kPa
(3.8 to 4.2 kgf/cm2, 54 to 60 psi)
553 to 623 kPa
(5.6 to 6.4 kgf/cm2, 80 to 90 psi)
Stall test1,126 to 1,226 kPa
(11.5 to 12.5 kgf/cm2, 163 to 178 psi)
1,664 to 1,864 kPa
(17.0 to 19.0 kgf/cm2, 241 to 270 psi)
Evaluation:
ProblemPossible cause
If the measured values at all positions are higher
Shift solenoid valve SLT defective

Regulator valve detective
If the measured values at all positions are lower

Shift solenoid valve SLT defective

Regulator valve detective

Oil pump defective
If pressure is low in the D position only
D position circuit fluid leak

Forward clutch defective
If pressure is low in the R position only

R position circuit fluid leak

Reverse clutch defective

1st and reverse brake defective

05KAP–02
– DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)05–221
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
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:

Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50
to 80
C (122 to 176
F).

Do not continuously run this test for longer than 10 seconds.

To ensure safety, do 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 Intelligent Tester II 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: 2,400
150 rpm
(8) Do the same test in the R position.
Stall speed: 2,400
150 rpm
Evaluation:
ProblemPossible cause
(a) Stall engine speed is low in D and R positions

Engine power output may be insufficient

Stator 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

Line pressure is too low

Forward clutch slipping

One–way clutch No.2 not operating properly
(c) Stall engine speed is high in R position

Line pressure is too low

Reverse clutch slipping

1st and reverse brake slipping
(d) Stall engine speed is high in D and R positions
Line pressure is too low

Improper fluid level