engine TOYOTA AVALON 2001 Service Repair Manual
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Page 775 of 1897
DI-164
- DIAGNOSTICSAUTOMATIC TRANSAXLE
320 Author: Date:
2001 AVALON (RM808U)
(b) Clearance the DTC.
The following operation will erase the DTC and freeze
frame data. Operating an OBD II scan tool (complying
with SAE J1978) or TOYOTA hand-held tester to erase
the codes (See the OBD II scan tool's instruction book for
operating instructions.).
4. ROAD TEST
NOTICE:
Perform the test at normal operating ATF temperature 50 - 80 °C (122 - 176 °F).
(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 to see that 1 " 2, 2 " 3 and 3 " O/D up-shift takes place,and that the shift points conform
the automatic shift schedule (See page SS-24).
HINT:
O/D Gear Up-shift Prohibition Control (1. Coolant temp. is 60 °C (140 °F) or less. 2. If there is a 10
km/h (6 mph) difference between the set cruise control speed and vehicle speed.)
O/D Gear Lock-up Prohibition Control (1. Brake pedal is depressed. 2. Coolant temp. 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 and 3 " O/D up-shifts.
(3) Check for abnormal noises and vibration.
Run at the D position lock-up or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be
due to loss of balance in the differential torque converter clutch, etc.
(4) Check kick-down operation.
While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick-down
vehicle speed limits for 2 " 1, 3 " 2 and O/D " 3 kick-downs conform to those indicated in the
automatic shift schedule (See page SS-24).
(5) Check abnormal shock and slip at kick-down.
(6) Check the lock-up mechanism.
Drive in D position, O/D gear, at a steady speed (lock-up ON) of about 60 km/h (37 mph).
Lightly depress the accelerator pedal and check that the engine speed does not change
abruptly.
If there is a big jump in engine speed, there is no lock-up.
(b) 2 position test
Shift into the 2 position and fully depress the accelerator pedal and check the following points:
(1) Check up-shift operation.
Check to see that the 1 " 2 up-shift takes place and that the shift point conforms to the automatic
shift schedule (See page SS-24).
HINT:
There is no O/D up-shift and lock-up in the 2 position.
(2) Check engine braking.
While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine
braking effect.
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and
down-shift.
Page 776 of 1897
D07227D07228D07756
Column Shift:
Floor Shift:
- DIAGNOSTICSAUTOMATIC TRANSAXLE
DI-165
321 Author: Date:
2001 AVALON (RM808U)
(c) L position test
Shift into the 2 position and fully depress the accelerator pedal and check the following points:
(1) Check no up-shift.
While running in the L position, check that there is no up-shift to 2nd gear.
(2) Check engine braking.
While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test
Shift into the R position and fully depress the accelerator pedal and check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from people and obstruction.
(e) P position test
Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking
brake. Then, check to see that the parking lock pawl holds the vehicle in place.
5. BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transaxle are at
normal operating temperature.
Fluid temp.: 70 - 80 °C (158 - 176 °F)
Only use the COOL range on the dipstick as a rough refer-
ence when the fluid is replaced or the engine does not
run.
(1) Park the vehicle on a level surface and set the park-
ing brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into all positions from P
to L position and return to P position.
Page 777 of 1897
AT3417
OK if hot
Add if hot
AT4657
AT8562
AT3417
OK if hot
Add if hot DI-166
- DIAGNOSTICSAUTOMATIC TRANSAXLE
322 Author: Date:
2001 AVALON (RM808U)
(3) Pull out the dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range.
If the level is not within the range, add new fluid.
Fluid type: ATF D-II or DEXRON®III (DEXRON®II)
NOTICE:
Do not overfill.
After filling ATF, check the oil level securely then
drive a vehicle.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(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: 4.75 liters (5.0 US qts, 4.2 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.
Page 778 of 1897
AT4252
0 - 1 mm (0 - 0.04 in.)
Q00199
D02450P N
R
- DIAGNOSTICSAUTOMATIC TRANSAXLE
DI-167
323 Author: Date:
2001 AVALON (RM808U)
(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 adjusting
nuts.
(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 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 downward.
(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.
Page 779 of 1897
Q04700
Neutral Basic Line
BoltBolt
Groove DI-168
- DIAGNOSTICSAUTOMATIC TRANSAXLE
324 Author: Date:
2001 AVALON (RM808U)
(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-199.
(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 pressing 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.
Quickly read the stall speed at this time.
Stall speed: 2,325 - 2,775 rpm
(7) Do the same test in R position.
Stall speed: 2,325 - 2,775 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 clutch 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
Page 780 of 1897
- DIAGNOSTICSAUTOMATIC TRANSAXLE
DI-169
325 Author: Date:
2001 AVALON (RM808U) (c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st & 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 conditions of the O/D direct clutch, forward clutch,
and 1st & 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.
Time lag: N " D Less than 1.2 seconds
In the same manner, measure the time lag for N " R.
Time lag: N " R Less than 1.5 seconds
Evaluation (If N " D time or N " R time lag is longer than the 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 & reverse brake worn
O/D one-way clutch not operating properly
Page 781 of 1897
DI-170
- DIAGNOSTICSAUTOMATIC TRANSAXLE
326 Author: Date:
2001 AVALON (RM808U)
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-33
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 pressing 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 the specified value, recheck the throttle cable adjustment and retest.
Evaluation:
ProblemPossible cause
If the measured values at all positions are higher
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured values at all positions 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 & reverse brake defective
Page 783 of 1897
DI02I-07
- DIAGNOSTICSAUTOMATIC TRANSAXLE
DI-175
331 Author: Date:
2001 AVALON (RM808U)
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 in 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.
Chapter 1: Electronic circuit matrix chart
SymptomSuspect AreaSee page
No up-shift (A particular gear, from 1st to 3rd gear, is not up-
shifted)ECMIN-30
No up-shift (3rd " O/D)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI-206
DI-203
IN-30
No down-shift (O/D " 3rd)ECMIN-30
No down-shift (A particular gear, from 3rd to 1st gear, is not
down-shifted)ECMIN-30
No lock-up or No lock-up offECMIN-30
Shift point too high or too lowECMIN-30
Up-shift to 2nd while in L positionECMIN-30
Up-shift to 3rd while in 2 positionECMIN-30
Up-shift to O/D from 3rd while O/D main switch is OFF1. O/D main switch & O/D OFF indicator light circuit
2. ECMDI-206
IN-30
Up-shift to O/D from 3rd while engine is coldECMIN-30
Harsh engagement (N " D)ECMIN-30
Harsh engagement (Any driving position)ECMIN-30
Poor accelerationECMIN-30
Engine stalls when starting off or stoppingECMIN-30
No kick-downECMIN-30
Page 784 of 1897
DI-176
- DIAGNOSTICSAUTOMATIC TRANSAXLE
332 Author: Date:
2001 AVALON (RM808U)
Chapter 2: On-vehicle repair
(: A541E automatic transaxle repair manual Pub. No. RM741U)
SymptomSuspect AreaSee page
Vehicle does not move in any forward position and reverse posi-
tion
1. Manual valve
2. Throttle valve
3. Primary regulator valve
4. Off-vehicle repair matrix chart
-
Vehicle does not move in R positionOff-vehicle repair matrix chart-
No up-shift (1st " 2nd)1. 1-2 shift valve
2. Off-vehicle repair matrix chart
-
No up-shift (2nd " 3rd)1. 2-3 shift valve
2. Off-vehicle repair matrix chart
-
No up-shift (3rd " O/D)1. 3-4 shift valve
2. Off-vehicle repair matrix chart
-
No down-shift (O/D " 3rd)3-4 shift valve
No down-shift (3rd " 2nd)2-3 shift valve
No down-shift (2nd " 1st)1-2 shift valve
No lock-up or No lock-up off1. Lock-up relay valve
2. Off-vehicle repair matrix chart
-
Harsh engagement (N " D)1. C1 accumulator
2. Off-vehicle repair matrix chart
-
Harsh engagement (N " R)
1. C2 accumulator
2. No.1 accumulator control valve
3. Off-vehicle repair matrix chart
-
Harsh engagement (N " L)Low coast modulator valve
Harsh engagement (Lock-up)1. Lock-up relay valve
2. Off-vehicle repair matrix chart
-
Harsh engagement (1st " 2nd " 3rd " O/D)
1. Throttle modulator valve
2. Cut back valve
3. Throttle valve
Harsh engagement (2nd " 3rd)C2 accumulator
Harsh engagement (3rd " O/D)B0 accumulator
Harsh engagement (O/D " 3rd)1. C0 accumulator
2. B
0 accumulator
Slip or shudder (Forward and reverse)
1. Throttle valve
2. Oil strainer
3. Off-vehicle repair matrix chart
-
No engine braking (1st: L position)1. Low coast modulator valve
2. Off-vehicle repair matrix chart
-
No engine braking (2nd: 2 position)1. 2nd coast modulator valve
2. Off-vehicle repair matrix chart
-
No kick-down
1. 1-2 shift valve
2. 2-3 shift valve
3. 3-4 shift valve
Page 785 of 1897
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DI-177
333 Author: Date:
2001 AVALON (RM808U)
Chapter 3: Off-vehicle repair
(: A541E automatic transaxle repair manual Pub. No. RM741U)
SymptomSuspect AreaSee page
Vehicle does not move in any forward position and reverse posi-
tion
1. Front and rear planetary gear
2. O/D planetary gear
3. O/D one-way clutch (F
0)
4. O/D direct clutch (C
0)
5. Forward clutch (C
1)
6. O/D brake (B
0)
Vehicle does not move in R position
1. Front and rear planetary gear unit
2. Direct clutch (C
2)
3. O/D direct clutch (C
0)
4. 1st & reverse brake (B
3)
No up-shift (1st " 2nd)1. No. 1 one-way clutch (F1)
2. 2nd brake (B
2)
No up-shift (2nd " 3rd)Direct clutch (C2)
No up-shift (3rd " O/D)O/D brake (B0)
No lock-up or No lock-up offTorque converter clutch-
Harsh engagement (N " D)
1. Forward clutch (C1)
2. O/D one-way clutch (F
0)
3. No. 2 one-way clutch (F
2)
Harsh engagement (N " R)1. Direct clutch (C2)
2. 1st & reverse brake (B
3)
Harsh engagement (Lock-up)Torque converter clutch-
Slip or shudder (Forward position: After warm-up)
1. Torque converter clutch
2. O/D direct clutch (C
0)
3. Forward clutch (C
1)
4. O/D one-way clutch (F
0)
Slip or shudder (R position)
1. Direct clutch (C2)
2. 1st & reverse brake (B
3)
3. O/D direct clutch (C
0)
Slip or shudder (1st)No. 2 one-way clutch (F2)
Slip or shudder (2nd)1. No. 1 one-way clutch (F1)
2. 2nd brake (B
2)
Slip or shudder (3rd)Direct clutch (C2)
Slip or shudder (O/D)O/D brake (B0)
No engine braking (1st ~ 3rd: D position)2nd brake (B2)
No engine braking (1st: L position)1st & reverse brake (B3)
No engine braking (2nd: 2 position)2nd coast brake (B1)
Poor acceleration (All position)1. Torque converter clutch
2. O/D planetary gear-
Poor acceleration (O/D)1. O/D direct clutch (C0)
2. O/D planetary gear
Large shift shock or engine stalls when starting off or stoppingTorque converter clutch-