clutch TOYOTA AVENSIS 2005 Service Repair Manual

D09693
D03576Pawl Shaft Clamp
D03875
E
D25511
Dimension (1)
Dimension (2)
D08087
Thrust Bearing Race No.1
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−61
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the parking lock pawl shaft.
(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
(d) Using a straight edge and vernier calipers as shown in the
illustration, measure the gap between the top of the differ-
ential drive pinion in the underdrive planetary gear and
contact surface of the transaxle case and housing (Di-
mension E).
NOTICE:
Note down the dimension E as it is necessary for the follow-
ing process.
(e) As shown in the illustration, measure the 2 places of the
transaxle housing, calculate the dimension F using the
formula.
NOTICE:
Note down the dimension F as it is necessary for the follow-
ing process.
HINT:
Dimension F = Dimension (1)−Dimension (2)
124. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust bearing race No.1 to the transaxle case
while checking its direction.
Bearing race diameter: mm (in.)
InsideOutside
Bearing race39.5 (1.555)45.8 (1.803)

D26710
Thrust Needle
Roller BearingMultiple Disc
Clutch Clutch
Hub
D26711
Thrust Needle
Roller BearingMultiple Disc
Clutch Clutch
Hub
D03820
Thrust Needle
Roller Bearing
D03574
Forward Clutch Assy
40−62
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Coat the thrust needle roller bearing and race with yellow
petrolatum, install them onto the multiple disc clutch hub.
Thrust bearing and race diameter: mm (in.)
InsideOutside
Thrust Bearing36.4 (1.433)52.2 (2.055)
(c) Coat the needle roller bearing with ATF.
(d) Install the needle roller bearing to the multiple clutch hub.
Bearing diameter: mm (in.)
InsideOutside
Bearing23.6 (0.929)44 (1.732)
(e) Install the multiple clutch hub to the transaxle case.
125. INSTALL FORWARD CLUTCH ASSY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward
clutch.
Thrust bearing diameter: mm (in.)
InsideOutside
Thrust Bearing33.58 (1.3220)51.9 (2.043)
NOTICE:
Install the thrust bearing properly so that the no colored
race or blue ink jet race will be visible.
(c) Install the forward clutch to the forward clutch assy.
NOTICE:
SAlign the splines of all discs in the forward clutch with
those of multiple clutch hub to assemble them se-
curely.
SBe careful not to damage the bush inside of the for-
ward clutch hub during installing.

D03573
D26450
Differential
Gear Assy
D25506
Thrust Bearing
Underdrive
Race No.2Underdrive Planetary
Gear Assy
Forward Clutch
Assy
Differential Gear Assy
Forward Clutch
Assy
D25505
Thrust
Needle
Roller Bearing
Differential Gear Assy
Underdrive Planetary
Gear Assy
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−63
U151E, U151F A/T REPAIR MANUAL (RM1021U)
126. INSTALL OVERDRIVE BRAKE GASKET
(a) Install the 2 new overdrive brake gaskets.
127. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assy to the transaxle case.
128. INSTALL THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Install the thrust bearing underdrive race No.2 to the un-
derdrive planetary gear assy.
129. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula
and values of Dimension E and F that ware measured
when installing cylindrical roller bearing and underdrive
planetary gear. Select an appropriate underdrive plane-
tary gear thrust bearing race No. 2 which satisfies the spe-
cified end play value, and install it.
End play: 0.498−0.993 mm (0.01961−0.03909 in.)
HINT:
End play = Dimension F−Dimension E−thrust bearing thick-
ness 2.5 mm (0.0984 in.)−underdrive thrust bearing race No.
2 thickness.
Race thickness: mm (in.)
F−EThickness
Less than 7.72 (0.3039)3.5 (0.138)
7.72 (0.3039)3.8 (0.150)

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.

–
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


05–32
–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E) DTC No.
(See Page) Memory
*1
MIL
Trouble Area
Detection Item
P2111
( 05–177 )Throttle Actuator Control System
– Stuck OpenThrottle actuator
 Throttle body assembly
 Throttle valve

P2112
( 05–177 )Throttle Actuator Control System
– Stuck ClosedSame as DTC P2111
P2118
( 05–179 )Throttle Actuator Control Motor
Current Range/PerformanceOpen in ETCS power source circuit
 ETCS fuse
 ECM

P2119
( 05–182 )Throttle Actuator Control Throttle
Body Range/PerformanceElectronic throttle control system
 ECM
P2120
( 05–184 )Throttle/Pedal Position Sensor/
Switch ”D” CircuitAccelerator pedal position sensor
 ECM
P2121
( 05–192 )Throttle/Pedal Position Sensor/
Switch ”D” Circuit Range/Perfor-
manceAccelerator pedal position sensor circuit
 Accelerator pedal position sensor
 ECM

P2122
( 05–184 )Throttle/Pedal Position Sensor/
Switch ”D” Circuit Low Input
Accelerator pedal position sensor
 Open in VCP1 circuit
 Open or ground short in VPA1 circuit
 ECM

P2123
( 05–184 )Throttle/Pedal Position Sensor/
Switch ”D” Circuit High InputAccelerator pedal position sensor
 Open in EPA circuit
 ECM

P2125
( 05–184 )Throttle/Pedal Position Sensor/
Switch ”E” CircuitAccelerator pedal position sensor
 ECM
P2127
( 05–184 )Throttle/Pedal Position Sensor/
Switch ”E” Circuit Low Input
Accelerator pedal position sensor
 Open in VCP2 circuit
 Open or ground short in VPA2 circuit
 ECM

P2128
( 05–184 )Throttle/Pedal Position Sensor/
Switch ”E” Circuit High InputAccelerator pedal position sensor
 Open in EPA2 circuit
 ECM

P2135
( 05–66 )Throttle/Pedal Position Sensor/
Switch ”A”/”B” Voltage Correla-
tionVTA1 and VTA2 circuits are short–circuited
 Throttle position sensor (built into throttle body)
 ECM

P2138
( 05–184 )Throttle/Pedal Position Sensor/
Switch ”D”/”E” Voltage Correla-
tionVPA1 and VPA2 circuits are short circuited
 Accelerator pedal position sensor
 ECM

P2195 *4
( 05–74 )Oxygen Sensor Signal Stuck
Lean (Bank 1 Sensor 1)
Open or short in heated oxygen sensor circuit
 Heated oxygen sensor (Sensor 1)
 Heated oxygen sensor heater (Sensor 1)
 EFI relay
 Air induction system
 Fuel pressure
 Injector
 ECM

P2196 *4
( 05–74 )Oxygen Sensor Signal Stuck
Rich (Bank 1 Sensor 1)Same as DTC P2195
P2716
( 05–286 )Pressure Control Solenoid ”D”
Electrical (Shift Solenoid SLT)Electronic control automatic transaxle
P2769
( 05–289 )Torque Converter Clutch Sole-
noid Circuit Low (Shift Solenoid
Valve SL)
Electronic control automatic transaxle

–
DIAGNOSTICS SFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–33
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)DTC No.
(See Page) Memory
*1
MIL
Trouble Area
Detection Item
P2770
( 05–289 )Torque Converter Clutch Sole-
noid Circuit High (Shift Solenoid
Valve SL)
Electronic control automatic transaxle
B2799
(*3)Engine Immobilizer System Mal-
functionImmobilizer system
*1: MIL (Malfunction Indicator Lamp) illuminates.
*2: MIL illuminates or flashes continuously.
*3: See page 05–1625 of Pub. No. RM1018E AVENSIS.
*4: Euro–OBD vehicles

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


05–246–
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E) P0787
( 05–274 )
Shift/Timing Solenoid Low
(Shift Solenoid Valve ST)
Short in shift solenoid valve ST circuit

Shift solenoid valve ST

ECM

P0788
( 05–274 )Shift/Timing Solenoid High
(Shift Solenoid Valve ST)
Open in shift solenoid valve ST circuit

Shift solenoid valve ST

ECM

P0973
( 05–277 )Shift Solenoid ”A” Control Circuit
Low (Shift Solenoid Valve S1)
Short in shift solenoid valve S1 circuit

Shift solenoid valve S1

ECM

P0974
( 05–277 )Shift Solenoid ”A” Control Circuit
High (Shift Solenoid Valve S1)
Open in shift solenoid valve S1 circuit

Shift solenoid valve S1

ECM

P0976
( 05–280 )Shift Solenoid ”B” Control Circuit
Low (Shift Solenoid Valve S2)
Short in shift solenoid valve S2 circuit

Shift solenoid valve S2

ECM

P0977
( 05–280 )Shift Solenoid ”B” Control Circuit
High (Shift Solenoid Valve S2)
Open in shift solenoid valve S2 circuit

Shift solenoid valve S2

ECM

P0998
( 05–283 )Shift Solenoid ”F” Control Circuit
Low (Shift Solenoid Valve SB)
Short in shift solenoid valve SB circuit

Shift solenoid valve SB

ECM

P0999
( 05–283 )Shift Solenoid ”F” Control Circuit
High (Shift Solenoid Valve SB)
Open in shift solenoid valve SB circuit

Shift solenoid valve SB

ECM

P2716
( 05–286 )Pressure Control Solenoid ”D”
Electrical
(Shift Solenoid Valve SLT)
Open or short in shift solenoid valve SLT circuit

Shift solenoid valve SLT

ECM

P2769
( 05–289 )Torque Converter Clutch Sole-
noid Circuit Low
(Shift Solenoid Valve SL)
Short in shift solenoid valve SL circuit

Shift solenoid valve SL

ECM

P2770
( 05–289 )Torque Converter Clutch Sole-
noid Circuit High
(Shift Solenoid Valve SL)
Open in shift solenoid valve SL circuit

Shift solenoid valve SL

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