transmission TOYOTA AVENSIS 2003 Service Owner's Guide

03±48
±
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
Shift schedule(When kick down switch turns ON)
D range
(Throttle valve fully opened) 1

2
2
3
3
4
4
3
3
2
2
1
(Throttle valve fully closed) 3
4
4
3
2 range
(Throttle valve fully opened) 1
2
3
2
2
1
L range
(Throttle valve fully opened) 2
1
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
158 ± 173 km/h (98 ± 108 mph)
150 ± 165 km/h (93 ± 103 mph)
94 ± 103 km/h (58 ± 64 mph)
46 ± 53 km/h (29 ± 33 mph)
36 ± 43 km/h (22 ± 27 mph)
16 ± 22 km/h (10 ± 14 mph)
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
46 ± 53 km/h (29 ± 33 mph)
50 ± 57 km/h (31 ± 35 mph)
Lock±up point Throttle valve opening 5 %
O/D gear Lock±up ON
Lock±up OFF
59 ± 67 km/h (37 ± 42 mph)
55 ± 63 km/h (34 ± 39 mph)
U241E (1AZ±FE) (RHD)
Line pressure (Wheel locked)
Engine idlingD range
R range
AT stall (Throttle valve fully opened) D range
R range
372 ± 412 kPa (3.8 ± 4.2 kgf cm2, 53 ± 60 psi)
672 ± 742 kPa (6.9 ± 7.6 kgf cm2, 97 ± 108 psi)
931 ± 1,031 kPa (9.5 ± 10.5 kgf cm
2, 135 ± 150 psi)
1,768 ± 1,968 kPa (18.0 ± 20.1 kgf cm2, 256 ± 285 psi)
Engine stall revolution D and R range2,550
150 rpm
Time lag N
D range
N
R rangeLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed
(A/C OFF) N range
650
50 rpm
Drive plate runout Max.
Torque converter clutch runout Max.0 20 mm (0.0079 in.)
0 30 mm (0.0118 in.)
Differential oil seal drive in depthLH side
RH side0
0.5 mm (0
0.020 in.)
0
0.5 mm (0
0.020 in.)
Shift schedule
D range
(Throttle valve fully opened) 1
2
2
3
3
4
4
3
3
2
2
1
(Throttle valve fully closed) 3
4
4
3
2 range
(Throttle valve fully opened) 1
2
3
2
2
1
L range
(Throttle valve fully opened) 2
1
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
158 ± 173 km/h (98 ± 108 mph)
150 ± 165 km/h (93 ± 102 mph)
94 ± 103 km/h (58 ± 64 mph)
46 ± 53 km/h (29 ± 33 mph)
36 ± 43 km/h (22 ± 27 mph)
16 ± 22 km/h (10 ± 13 mph)
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
46 ± 53 km/h (29 ± 33 mph)
50 ± 57 km/h (31 ± 35 mph)
Lock±up point Throttle valve opening 5 %
O/D gear Lock±up ON
Lock±up OFF
59 ± 67 km/h (37 ± 42 mph)
55 ± 63 km/h (34 ± 39 mph)
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±
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
03±49
AVENSIS REPAIR MANUAL (RM1018E)
U241E (1AZ±FE) (LHD)
Line pressure (Wheel locked)
Engine idlingD range
R range
AT stall (Throttle valve fully opened) D range
R range
372 ± 412 kPa (3.8 ± 4.2 kgf cm2, 53 ± 60 psi)
672 ± 742 kPa (6.9 ± 7.6 kgf cm2, 97 ± 108 psi)
931 ± 1,031 kPa (9.5 ± 10.5 kgf cm
2, 135 ± 150 psi)
1,768 ± 1,968 kPa (18.0 ± 20.1 kgf cm2, 256 ± 285 psi)
Engine stall revolution D and R range2,550
150 rpm
Time lag N
D range
N
R rangeLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed
(A/C OFF) N range
650
50 rpm
Drive plate runout Max.
Torque converter clutch runout Max.0 20 mm (0.0079 in.)
0 30 mm (0.0118 in.)
Differential oil seal drive in depthLH side
RH side0
0.5 mm (0
0.020 in.)
0
0.5 mm (0
0.020 in.)
Shift schedule
D range
(Throttle valve fully opened) 1
2
2
3
3
4
4
3
3
2
2
1
(Throttle valve fully closed) 3
4
4
3
2 range
(Throttle valve fully opened) 1
2
3
2
2
1
L range
(Throttle valve fully opened) 2
1
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
158 ± 173 km/h (98 ± 108 mph)
119 ± 133 km/h (74 ± 83 mph)
83 ± 92 km/h (52 ± 57 mph)
46 ± 53 km/h (29 ± 33 mph)
36 ± 43 km/h (22 ± 27 mph)
16 ± 22 km/h (10 ± 13 mph)
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
46 ± 53 km/h (29 ± 33 mph)
50 ± 57 km/h (31 ± 35 mph)
Shift schedule(When kick down switch turns ON)
D range
(Throttle valve fully opened) 1
2
2
3
3
4
4
3
3
2
2
1
(Throttle valve fully closed) 3
4
4
3
2 range
(Throttle valve fully opened) 1
2
3
2
2
1
L range
(Throttle valve fully opened) 2
1
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
158 ± 173 km/h (98 ± 108 mph)
150 ± 165 km/h (93 ± 102 mph)
94 ± 103 km/h (58 ± 64 mph)
46 ± 53 km/h (29 ± 33 mph)
36 ± 43 km/h (22 ± 27 mph)
16 ± 22 km/h (10 ± 13 mph)
53 ± 62 km/h (33 ± 39 mph)
102 ± 111 km/h (63 ± 69 mph)
46 ± 53 km/h (29 ± 33 mph)
50 ± 57 km/h (31 ± 35 mph)
Lock±up point Throttle valve opening 5 %
O/D gear Lock±up ON
Lock±up OFF
59 ± 67 km/h (37 ± 42 mph)
55 ± 63 km/h (34 ± 39 mph)
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030AA±10
03±50
±
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
U341E
Part TightenedN
mkgf
cmft
lbf
Park/neutral position switch x Transaxle Bolt
Nut5.4
6.955
7048 in.
lbf
61 in.
lbf
Control shaft lever x Park/neutral position switch131309
Battery carrier x Body1313210
Engine hanger x Engine3838728
Drain plug x Oil pan4950036
Transaxle x Engine Bolt A:
Bolt B:
Bolt C:64
46
23650
470
23547
34
17
Torque converter clutch x Drive plate2828520
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket FR x Transaxle6465347
Center member x Body Bolt A:4545933
Center member x Suspension memberBolt B:
BoltC:96
52979
53071
38
Engine mounting insulator RR x Engine mounting bracket RR8788764
Engine mounting insulator RR x Suspension member5253038
Engine mounting insulator FR x Engine mounting bracket FR5253038
Engine mounting bracket LH x Transaxle6465347
Engine mounting insulator LH x Body Bolt A:
Nut B:52
80530
81538
59
Starter x Transaxle3737727
Starter wire x Starter9.810087 in.
lbf
Froor panel brace x Body3030222
Oil filler tube x Transaxle Bolt A:121229
Oil cooler tube clamp x Oil filler tubeBolt B:5.55649 in.
lbf
Oil cooler outlet tube x Transaxle3535725
Oil cooler inlet tube x Transaxle3535725
Wire harness clamp bracket x Transaxle121229
Wire harness x Transaxle Bolt A:
Bolt B:5
2651
26544 in.
lbf
19
Control cable bracket x Transaxle121229
Control cable support x Transaxle121229
Air cleaner assy x Body7.07162 in.
lbf
Cylinder head cover No. 2 x Engine7.07162 in.
lbf
Speed sensor x Transaxle5.45548 in.
lbf
Transmission wire x Transaxle5.45548
Solenoid valve x Valve body Bolt A:
Bolt B:11
1111 0
11 08
8
Valve body x Transaxle1111 08
ATF temperature sensor x Valve body1111 08
Oil strainer x Valve body1111 08
Oil pan x Transaxle7.88069 in.
lbf
Floor shift assembly x Body121229
Control cable x Control shaft lever121229
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±
SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION / TRANSAXLE
03±51
AVENSIS REPAIR MANUAL (RM1018E)
U241E
Part TightenedN

mkgf
cmft
lbf
Park/neutral position switch x Transaxle Bolt
Nut5.4
6.955
7048 in.
lbf
61 in.
lbf
Control shaft lever x Park/neutral position switch131309
Battery carrier x Body1313210
Engine hanger x Engine3838728
Drain plug x Oil pan4950036
Transaxle x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Torque converter clutch x Drive plate4142030
Engine mounting bracket RR x Transaxle6465247
Engine mounting bracket FR x Transaxle6465247
Center member x Body4545933
Center member x Suspension member Bolt B:
Boltc:96
52979
53071
38
Engine mounting insulator RR x Engine mounting bracket RR8788764
Engine mounting insulator RR x Suspension member5253038
Engine mounting insulator FR x Engine mounting bracket FR5253038
Engine mounting bracket LH x Transaxle6465347
Engine mounting insulator LH x Body Bolt A:
Nut B:52
80530
81638
59
Starter x Transaxle3737727
Starter wire x Starter9.810087 in.
lbf
Oil filler tube x Transaxle5.55649 in.
lbf
Oil cooler tube clamp x Oil filler tube5.45547 in.
lbf
Oil cooler outlet tube x Transaxle3434725
Oil cooler inlet tube x Transaxle3434725
Wire harness clamp bracket x Transaxle1313210
Wire harness x Transaxle Bolt A:
Bolt B:5.0
8.451
8644 in.
lbf
74 in.
lbf
Control cable bracket x Transaxle121228
Control cable clamp x Transaxle121229
Air cleaner assy x Body5.05049 in.
lbf
Cylinder head cover sub±assy No. 1 x Engine9.09280 in.
lbf
Transmission wire x Transaxle5.45548 in.
lbf
Solenoid valve x Valve body Bolt A:
Bolt B:6.6
1167
11 058 in.
lbf
8
Valve body x Transaxle1111 08
Manual detent spring x Valve body1111 08
Oil strainer x Valve body1111 08
Oil pan x Transaxle7.88069 in.
lbf
Floor shift assy x Body121229
Control cable x Control shaft lever121229
Control cable x Body Bolt
Nut5.0
5.050
5043 in.
lbf
43 in.
lbf
Speed sensor x Transaxle121229
Drive shaft bearing cace x Bearing bracket6465047
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031DZ±02
03±6
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle position sensor x Throttle body assy2.02018 in.
lbf
ISC valve x Throttle body assy3.73833 in.
lbf
Accelerator control cable bracket x Throttle body assy1313310
Throttle body assy x Intake manifold3030622
Throttle body bracket x Cylinder block sub±assy (1ZZ±FE)3030622
Manifold stay No. 2 x Throttle body assy (M/T)1313310
Accelerator control cable assy x Accelerator control cable bracket131299
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold3030622
Accelerator control cable assy x Throttle body assy131299
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
Intake manifold x Cylinder head sub±assy3030622
Variable resister x Body (Leaded gasoline (Steering position LHD))5.05144 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold9.09280 in.
lbf
Throttle body bracket x Throttle body assy2121015
Throttle body bracket x Cylinder head sub±assy2121015
Ground terminal x Throttle body bracket8.48674 in.
lbf
Wire harness protector x Throttle body bracket8.48674 in.
lbf
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Accelerator pedal x Body5.45548 in.
lbf
Knock control sensor x Cylinder block2020415
Engine cover bracket x Cylinder head3838828
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Intake shutter assy x Intake air connector2121415
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Air tube No. 2 x Transmission2525518
Air tube No. 1 x Air tube No. 22525518
Camshaft position sensor x Camshaft oil seal retainer8.89079 in.
lbf
Return tube sub±assy x Engine hanger No. 19.09280 in.
lbf
Crankshaft position sensor x Oil pump assy8.89079 in.
lbf
ECM x Body5.55649 in.
lbf
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030NC±02
03±52
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSMISSION / TRANSAXLE
SERVICE DATA
C50, C250
Transmission case oil seal drive in depth9.9
0.3 mm (0.390
0.012 in.)
Transaxle case oil seal drive in depth1.9
0.3 mm (0.075
0.012 in.)
E354, E357
Transmission case oil seal drive in depth3.5
0.5 mm (0.138
0.020 in.)
Transaxle case cover oil seal drive in depth0
0.5 mm (0
0.020 in.)
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030ND±02
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
03±53
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
Floor shift transmission control cable assy x Body5.05144 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
FLOOR SHIFT SHIFT LEVER ASSY
Floor shift shift lever assy x Body121229
MANUAL TRANSAXLE ASSY (1ZZ±FE/ 3ZZ±FE)
Filler and drain plugs3940029
Engine hanger set bolt3838728
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
47
23650
480
23047
35
17
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Starter assy x Manual transaxle assy3738027
Starter wire set nut131309
Clutch release cylinder assy x TransaxleBolt A:
Bolt B:
Bolt C:25
14
5.0250
141 2119
10
44 in.
lbf
Manual transaxle assy x Wire harness clmap Bolt A:
Bolt B:26
19260
19519
14
Manual transaxle assy x Ground cable Bolt A:
Bolt B:26
40260
41019
30
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head cover No.2 x Engine7.07162 in.
lbf
Hood set bolt1313310
MANUAL TRANSAXLE ASSY (1AZ±FE/ 1AZ±FSE)
Filler and drain plugs4950036
Engine hanger x Engine3838728
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Manual transaxle assy x Ground cableBolt A:
Bolt C:26
40260
41019
30
Manual transaxle assy x Wire harness clamp8.48574 in.
lbf
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:9.0
1292
12080 in.
lbf
9
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03±54
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Engine cover sub±assy No.1 x Engine9.09280 in.
lbf
Hood set bolt1313210
MANUAL TRANSAXLE ASSY (1CD±FTV)
Filler and drain plugs4950036
Engine hanger x Engine3737727
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:
Bolt D:
Bolt E:64
46
40
20
8.0653
469
408
200 8247
34
30
14
71 in.
lbf
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Accumulator to flexible hose tube x TransaxleBolt A:
Bolt B:
Bolt C:12
5.0
9.0120 51
929
44 in.
lbf
80 in.
lbf
Manual transaxle assy x Ground cable131319
Air tube No.2 x Transaxle2525518
Starter assy x Transaxle3738027
Starter wire set nut131309
Radiator reserve tank assy x Body6.06153 in.
lbf
Air tube No.1 x Engine2525518
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body7.07162 in.
lbf
Engine cover No.1 x Engine8.08271 in.
lbf
Hood set bolt1313310
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±
ENGINE CONTROL SYSTEMECD SYSTEM(1CD±FTV)
10±55
AVENSIS REPAIR MANUAL (RM1018E)
(c)Inspect the air assist system.
(1)Start the engine and check that the CHKENG does not light up.
(2)Allow the engine to warm up to normal operating temperature.
(3)Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 800
50 rpm
NOTICE:
Perform inspection under condition without electrical load.
(d)After checking the above (b) to (d), perform the driving test and check that there is no sense of incon- gruity.
3.INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch ON.
(c)Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value. Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depress: 2.6 to 4.5 V
(d)Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value.
Accelerator pedal released: 1.2 to 2.0 V
Accelerator pedal depress: 3.4 to 5.3 V
If you have no hand±held tester, measure voltage between terminals (VPA1 ± EP1, VPA2 ± EP2) of the ECM
connector (See page 05±549).
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A53763
E2PSW
10±38
±
ENGINE CONTROL SYSTEMSFI SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
2.INSPECT POWER STEERING OIL PRESSURE SEN- SOR
(a)Using a voltmeter, measure the voltage between termi-
nals PSW and E2.
Voltage:
ConditionVoltage (V)
Not spin the steering wheel at engine idling9 to 14
Spin the steering wheel at engine idling0 to 3
3.INSPECT THROTTLE BODY
(a)Inspect the throttle control motor for operating sound.(1)Turn the ignition switch ON.
(2)When turning the accelerator pedal position sensor lever, check the running sound of the motor.Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See page 10±39), wiring and ECM.
(b) Inspect the throttle position sensor.
(1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) When turning the accelerator pedal position sensor lever to the full±\
open position, check thatthe throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shown the
standard value.
Standard throttle valve opening percentage:
60 % or more
If operation is not as specified, check that the accelerator pedal positio\
n sensor (See page 10±39), wiring
and ECM.
If you have no hand±held tester, measure voltage between terminals (VTA1 ± E2, VTA2 ± E2) of the ECM
connector (See page 05±318).
(c) Inspect the air assist system.
(1) Start the engine and check that the CHK ENG does not light up.
(2) Allow the engine to warm up to normal operating temperature.
(3) Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700
50 rpm
NOTICE:
Perform inspection under condition without electrical load.
(d) After checking the above (b) to (d), perform the driving test and check that there is no sense of incon-
gruity.
4. INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a) Connect the hand±held tester to the DLC3.
(b) Turn the ignition switch ON.
(c) Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value.
Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depress: 2.6 to 4.5 V
(d) Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value. Accelerator pedal released: 1.2 to 2.0 V
Accelerator pedal depress: 3.4 to 5.3 V
If you have no hand±held tester, measure voltage between terminals (VPA ± EPA, VPA2 ± EPA2) of the ECM
connector (See page 05±318).
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