2005 TOYOTA AVENSIS transmission

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.

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.

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.

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)