clutch TOYOTA AVENSIS 2005 Service Repair Manual

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

05–222– DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Measure the time lag.
(1) 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 condition of the direct clutch, forward
clutch, and 1st and reverse brake.
NOTICE:

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

Be sure to allow 1 minute interval between tests.

Perform the test three times, and measure the time lags. Calculate the average value of the three
time lags.
(2) Connect an Intelligent Tester II to the DLC3.
(3) Fully apply the parking brake.
(4) Start and warm up the engine and check idle speed.
Idle speed: approx. 700 rpm (In N position and A/C OFF)
(5) Shift the 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
(6) In the same way, measure the time lag for N → R.
Time lag: N → R less than 1.5 seconds
Evaluation (If N → D or N → R time lag is longer than the specified):
ProblemPossible cause
N → D time lag is longer

Line pressure is too low

Forward clutch worn

One–way clutch No.2 not operating properly
N → R time lag is longer

Line pressure is too low

Reverse clutch worn

1st and reverse brake worn

G31165
E1
Electronically Controlled
Transmission Solenoid
R
E12SLECM
15
LG
4
SL+B
CPU
– DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)05–289
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P2769 TORQUE CONVERTER CLUTCH SOLENOID
CIRCUIT LOW (SHIFT SOLENOID VALVE SL)
DTC P2770 TORQUE CONVERTER CLUTCH SOLENOID
CIRCUIT HIGH (SHIFT SOLENOID VALVE SL)
CIRCUIT DESCRIPTION
The shift solenoid valve SL is turned ”ON” and ”OFF” by signals from the ECM in order to control the hydraulic
pressure operation, the lock–up relay valve, which then the controls operation of the lock–up clutch.
DTC No.DTC Detection ConditionTrouble Area
P2769ECM detects short in solenoid valve SL circuit (0.1 sec.) when
solenoid valve SL is operated (2–trip detection logic)
Short in shift solenoid valve SL circuit

Shift solenoid valve SL

ECM
P2770ECM detects open in solenoid valve SL circuit (0.1 sec.) when
solenoid valve SL is not operated (2–trip detection logic)
Open in shift solenoid valve SL circuit

Shift solenoid valve SL

ECM
MONITOR DESCRIPTION
Based on the signals from the Throttle Position Sensor, the Airflow Meter and the Crankshaft Position Sen-
sor, the ECM sends a signal to the shift solenoid valve SL to regulate the hydraulic pressure and provide
smoother gearshifts. The shift solenoid valve SL responds to commands from the ECM. The valve controls
the lock–up relay valve to perform the torque–converter lock–up function. If the ECM detects an open or
short circuit for shift solenoid valve SL, it will illuminate the MIL.
WIRING DIAGRAM
05CW7–06

G31165
E1
Electronically Controlled
Transmission SolenoidECM
20
E12 ST
2
Y
R–B
ST +B
CPU
05–274–
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From Februar y, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0787 SHIFT/TIMING SOLENOID LOW (SHIFT SOLENOID VALVE ST)
DTC P0788 SHIFT/TIMING SOLENOID HIGH (SHIFT SOLENOID VALVE ST)
CIRCUIT DESCRIPTION
The shift solenoid valve ST is used for shifting from the 3rd to 4th gear, and from the 4th to 3rd gear. Actuates
solenoid valves ST and SLT in accordance with the signals from the ECM, and guides this output pr\
essure
directly to 4–3 shift timing valve and 3–4 shift timing valve in order to regulate the line pressure that acts on
the B
1 brake and C1 clutch.
DTC No.DTC Detection ConditionTrouble Area
P0787ECM detects short in solenoid valve ST circuit 4 times when
solenoid valve ST is operated (1–trip detection logic)

Short in shift solenoid valve ST circuit

Shift solenoid valve ST

ECM
P0788ECM detects open in solenoid valve ST circuit 4 times when
solenoid valve ST is not operated (1–trip detection logic)
Open in shift solenoid valve ST circuit

Shift solenoid valve ST

ECM
MONITOR DESCRIPTION
The ECM commands gear shifts by turning the shift solenoid valves ”ON/OF\
F”. When there is an open or
short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and
stores the DTC. And the ECM performs the fail–safe function and turns the o\
ther shift solenoid valves in good
condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sen\
ding current to the circuit.)
(see page 05–241 ).
WIRING DIAGRAM
05CVW–07

05–268– DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0751 SHIFT SOLENOID ”A” PERFORMANCE
(SHIFT SOLENOID VALVE S1)
SYSTEM DESCRIPTION
The ECM uses signals from the vehicle speed sensor and speed sensor NT to detect the actual gear position
(1st, 2nd, 3rd or 4th gear).
Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical
problems of the shift solenoid valves and valve body.
DTC No.DTC Detecting ConditionTrouble Area
P0751The gear required by the ECM does not match the actual gear
when driving (2–trip detection logic)

Shift solenoid valve S1 remains open or closed

Valve body is blocked

Shift solenoid valve S1

Automatic transaxle (clutch, brake or gear etc.)

ECM
MONITOR DESCRIPTION
The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft
revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual
gear position (1st, 2nd, 3rd or 4th gear position). When the gear position commanded by the ECM and the
actual gear position are not same, the ECM illuminates the MIL.
Example:
When either condition (a) or (b) is met, the ECM detects a malfunction.
(a) The ECM commands the 1st gear, but the actual gear is 2nd.
(b) The ECM commands the 2nd gear, but the actual gear is 1st.
05CVV–05

G27219
Shift Solenoid Valve S1:
05–270–
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
2 INSPECT SHIFT SOLENOID VALVE(S1)
(a) Remove the shift solenoid valve S1.
(b) Measure the resistance according to the value(s) in the table below.
Standard:
Tester ConnectionSpecified Condition
20 C (68 F)
Solenoid Connector (S1) – Solenoid
Body (S1)11 to 15 Ω
(c) Connect positive (+) lead to the terminal of solenoid con-
nector, negative (–) lead to the solenoid body.
OK:
The solenoid makes an operating noise.
NG REPLACE SHIFT SOLENOID VALVE(S1)
OK
3 INSPECT TRANSMISSION VA LVE BODY ASSY(See chapter 2 in the problem
symptoms table)
( SEE PAGE 05–229 )
OK:
There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVEBODY ASSY
(See Pub. No. RM1018E, page 40–42)
OK
4 INSPECT TORQUE CONVERTER CLUTCH ASSY (See Pub. No. RM1018E,
page 40–37)
OK:
The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCHASSY
OK
REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (See Pub. No. RM1018E, page 40–11)

G30849
Instrument Panel J/B
S6
Stop Light SW
Engine Room R/BECM
STP
E1019
G–W 7
ID1
B–R 2C
2N 2ASTOP 110 2
22 IJ1
IJ112
21
G–B
B–R
FL MAIN
Battery11
12ALTG–W G–W
2A G–W
G–B
– DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)05–261
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
DTC P0724 BRAKE SWITCH ”B” CIRCUIT HIGH
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling while driving in lock–up condition, when
brakes are suddenly applied.
When the brake pedal is depressed, this switch sends a signals to the ECM. Then the ECM cancels the op-
eration of the lock–up clutch while braking is in progress.
DTC No.DTC Detecting ConditionTrouble Area
P0724
The stop light switch remains ON even when the vehicle is
driven in a GO (30 km/h) and STOP (3 km/h) fashion 10 times.
(2–trip detection logic).
Short in stop light switch signal circuit

Stop light switch

ECM
MONITOR DESCRIPTION
This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during ”stop
and go” driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM
stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) ten
times for two driving cycles in order to detect malfunction.
WIRING DIAGRAM
05KB2–02

A76724
A76714
A77338
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–11
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
22. REMOVE RADIATOR ASSY
(a) Remove the 2 bolts and relay block.
(b) Disconnect the connector and 2 harness clamps.
(c) Remove the 2 bolts, 2 radiator support uppers and radia-
tor.
23. REMOVE BATTERY
24. REMOVE BATTERY TRAY
25. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts, battery carrier and bracket.
26. REMOVE EFI FUEL PIPE CLAMP

(See Pub. No. RM1018E on page 11–11)
27. DISCONNECT FUEL TUBE SUB–ASSY

(See Pub. No. RM1018E on page 11–11)
28. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose.
29. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose from the heater core inlet tube.
30. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose from the heater core outlet tube.
31. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)

(See Pub. No. RM1018E on page 41–15)
32. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
33. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
34. SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
35. REMOVE GLOVE COMPARTMENT DOOR ASSY (See Pub. No. RM1018E on page 71–11)
36. REMOVE INSTRUMENT PANEL UNDER COVER SUB–ASSY NO.2
37. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junction
block.
(b) Pull out the engine wire.
(c) Remove the engine room relay block No.2 cover.
(d) Remove a nut, then disconnect a connector as shown in
the illustration.

A79320
(f)
(e)
A79296
A60622
14–12– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(e) Remove the bolt, then disconnect the ground terminal.
(f) Disconnect the ground terminal connector.
(g) Remove the nut and disconnect battery terminal B.
38. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V–ribbed belt tensioner clockwise slowly and
loosen it. Then, remove the fan and generator V belt and
put back the V–ribbed belt tensioner carefully.
39. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19–7)
40. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:
Secure the compressor and hoses off to the side instead of discharging the A/C system.
1ZZ–FE (See Pub. No. RM1018E on page 55–74)
3ZZ–FE (See Pub. No. RM1018E on page 55–70)
41. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and column hole cover silencer sheet.
42. SEPARATE STEERING INTERMEDIATE SHAFT (See Pub. No. RM1018E on page 50–9)
43. REMOVE FRONT DOOR SCUFF PLATE RH (See Pub. No. RM1018E on page 71–11)
44. REMOVE COWL SIDE TRIM BOARD RH (See Pub. No. RM1018E on page 71–11)
45. REMOVE FRONT FLOOR FOOTREST (RHD STEERING POSITION TYPE)
46. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and floor panel brace front.
47. REMOVE EXHAUST PIPE ASSY FRONT (See Pub. No. RM1018E on page 15–2)
48. REMOVE FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30–6)
SST 09930–00010

A76719
A62838SST
A62838SST
A76713
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–15
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Remove the through bolt, then detach the engine mount-
ing insulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the
suspension crossmember and engine mounting member.
60. REMOVE STARTER ASSY (See Pub. No. RM1018E on page 19–3)
61. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
62. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
63. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
64. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
65. REMOVE FLYWHEEL SUB–ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
flywheel.
SST 09960–10010 (09962–01000, 09963–01000)
66. REMOVE DRIVE PLATE & RING GEAR SUB–ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
drive plate & ring gear.
SST 09960–10010 (09962–01000, 09963–01000)
67. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
(b) Remove the 2 nuts which are used to secure the engine
wire.