TOYOTA AVENSIS 2005 Service Repair Manual

05JL7−01
G23405Transmission Wire
05 −540−
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U 151E)
AVENSIS Supplement (RM 1045E)
MANUAL SHIFTING TEST
1. PERFORM MANUAL SHIFTING TEST
HINT:
S With this test, it can be determined whether the trouble oc-
curs in the electrical circuit or is a mechanical problem in
the transaxle.
S If any abnormalities are found in the following test, the
problem is in the transaxle itself.
(a) Disconnect the transmission wire connector.
(b) Drive with the transmission wire disconnected. Shifting the shift lever to the D position to check whether
the shifting condition changes the table below.
Shift PositionShifting Condition
DNo Shift (Not Change)
HINT:
When driving with the transmission wire disconnected, the gear
position will be as follows:
S When the shift lever is in the D position, the gear is held
in the 4th position.
S When the shift lever is in the R or the P position, the gear
is also in the R or the P position respectively.
(c) Connect the transmission wire connector.
(d) Clear the DTC (see page 05 −557).

05JL6−01
G23404
SST SST
Test Plug A:
D Position (CO)Test Plug B:
R Position (C2) 05−538
− DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U151E)
AVENSIS Supplement (RM1045E)
HYDRAULIC TEST
1. PERFORM HYDRAULIC TEST
(a) Measure the line pressure.
NOTICE:
SPerform the test at the normal operation fluid temper-
ature the 50 to 80˚C(122 to176˚F)
SThe 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 performing the test.
SBe careful to prevent SST hose from interfering with
the exhaust pipe.
SThis check must be conducted after checking and ad-
justing engine.
SPerform under condition that A/C is OFF.
SWhen conducting stall test, do not continue more
than10 seconds.
(1) Warm up the ATF (Automatic Transmission Fluid).
(2) Lift the vehicle up.
(3) Remove the engine under cover.
(4) Connect hand−held tester to DLC3.
(5) Remove the test plug A on the transaxle case front
left side and install the SST.
SST 09992−00095 (09992−00231, 09992−00271)
NOTICE:
There is a difference in installation point between D posi-
tion and R position.
(6) Start the engine.
(7) Using hand−held tester, shift to D position and hold
3rd gear by active test, and measure the line pres-
sure in idling.
Specified line pressure:
ConditionD position
Idling372 to 412 kPa
(3.8 to 4.2 kgf/cm2, 54 to 60 psi)
(8) Turn the ignition switch off.

G23405Transmission Wire
− DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U151E)05−539
AVENSIS Supplement (RM1045E)
(9) Disconnect the connector of the transmission wire.
HINT:
Disconnect the connector only when performing the D position
stall test.
(10) Start the engine.
(11) Firmly depress the brake pedal, shift to the D posi-
tion, depress the accelerator pedal all the way down
and check the line pressure while the stall test is
performed.
Specified line pressure:
ConditionD position
Stall test931to1,031kPa
(9.5 to10.5 kgf/cm2,135 to150 psi)
(12) Turn the ignition switch off.
(13) Remove the SST, install the test plug A.
(14) Remove the test plug B, install the SST and start en-
gine.
SST 09992−00095 (09992−00231, 09992−00271)
(15) Connect the transmission wire connector, depress
the brake pedal firmly, shift to the R position and
check that the line pressure while the engine is id-
ling and during the stall test.
Specified line pressure:
ConditionR position
Idling672 to 742 kPa
(6.9 to 7.6 kgf/cm2,97to108 psi)
Stall test1,768 to1,968 kPa
(18.0 to 20.1kgf/cm2, 256 to 285 psi)
(16) Remove the SST, install the test plug B.
(17) Clear the DTC.
Evaluation:
ProblemPossible cause
If the measured values at all position are higherSShift solenoid valve (SLT) defective
SRegulator valve defective
If the measured values at all position are lower
SShift solenoid valve (SLT) defective
SRegulator valve defective
SOil pump defective
SU/D (Underdrive) direct clutch defective
If pressure is low in the D position onlySD position circuit fluid leak
SForward clutch defective
If pressure is low in the R position only
SR position circuit fluid leak
SReverse clutch defective
S1st and reverse brake defective

1306Y−02
A85745
8.0 (82, 71 in.
lbf)
Engine Cover Sub−assy No. 1 Radiator Support Opening Cover
N·m (kgf·cm, ft·lbf)
: Specified torque
7.0 (71, 62 in.
lbf)
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Engine Under Cover Sub−assy No. 1 Clip
Retainer
Clip
x5
x3 Cooler V Belt No. 1 Generator V Belt
Generator Assy
47 (475, 34)
31 (320, 23)
Differential Pressure
Sensor Assy
Exhaust Gas Temperature
Sensor Connector
5.5 (56, 49 in.
lbf)
Mass Air Flow Meter
Connector
− INTAKETURBOCHARGER SUB−ASSY (1CD−FTV)(From
September, 2003)13−9
AVENSIS Supplement (RM1045E)
TURBOCHARGER SUB−ASSY (1CD−FTV)(From September,
2003)
COMPONENTS

A85746
Union to Connector Tube Hose
Fuel Filter Assy Vacuum Reservoir Sub−assy
43 (440, 32)
43 (440, 32)
zGasket
zGasketCompression Spring
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasket
7.5 (76, 66 in.
lbf)
Exhaust Pipe Assy
30 (302, 22)
7.5 (76, 66 in.
lbf)
Heater Bracket
Heater Pump Assy25 (255, 18)
25 (255, 18)
7.5 (76, 66 in.
lbf)
18 (178, 13)
7.5 (76, 66 in.
lbf)
w/ Cold Area:
w/ Cold Area:
w/ Cold Area:
8.3 (85, 73 in.
lbf)
Air Tube No. 1
x2
43 (440, 32)
6.0 (61, 53 in.
lbf)
13−10− INTAKETURBOCHARGER SUB−ASSY (1CD−FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)

A85747
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasket
zGasket zGasket
20 (204, 15)
20 (204, 15)
20 (204, 15)
12 (122, 8.9)
60 (612, 44)
13 (135, 9.8)
36 (367, 27)
61 (622, 45)
56 (571, 41)
25 (255, 18)
Turbo Insulator No. 1
Exhaust Manifold Heat Insulator No. 2
Turbocharger Stay
Turbocharger Sub−assy
Turbo Oil Inlet Pipe
Sub−assy
Manifold Stay Manifold Stay No. 2
Exhaust Manifold
Converter Sub−assy Turbo Insulator No. 2
Turbo Water Pipe
Sub−assy No. 1
13 (135, 9.8)
56 (571, 41)
Turbo Water
Hose No. 2
Turbo Water
Hose No. 1
zGasket
12 (122, 8.9)
z
EGR Pipe Insulator
12 (122, 8.9)
x3x3
x2
x4
25 (255, 18)
Exhaust Gas Temperature
Sensor
Vacuum Transmitting
Pipe Sub−assy No. 2
30 (306, 22)
Vacuum Transmitting
Pipe Sub−assy No. 1
30 (306, 22)
x3
z
− INTAKETURBOCHARGER SUB−ASSY (1CD−FTV)(From
September, 2003)13−11
AVENSIS Supplement (RM1045E)

1302Z−04
A77123
SST
A60595E2 VC
13−6− INTAKETURBO CHARGER SYSTEM (1CD−FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
ON−VEHICLE INSPECTION
1. INSPECT INTAKE AIR SYSTEM
(a) Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between
the turbocharger outlet and cylinder head.
ConditionOperation
Clogged air cleanerClean or replace the element
Collapsed or deformed hosesRepair or replace
Leakage from connectionsCheck each connection and repair
Cracks in componentsCheck and replace
2. INSPECT EXHAUST SYSTEM
(a) Check for leakage or clogging between the cylinder head and turbocharger inlet and between the
turbocharger outlet and exhaust pipe.
ConditionOperation
Deformed componentsRepair or replace
Foreign material in passagesRemove
Leakage from componentsRepair or replace
Cracks in componentsCheck and replace
3. CHECK TURBOCHARGING PRESSURE
(a) Warm up the engine.
(b) Using a 3−way connector, connect SST (turbocharger
pressure gauge) to the hose leading to the intake air con-
nector.
SST 09992−00242
(c) While depressing the clutch pedal, press the accelerator
pedal down fully. Measure the turbocharging pressure at
the maximum speed (5,100 to 5,250 rpm).
Standard pressure:
15 to 45 kPa (0.15 to 0.46 kgf/cm
2, 2.2 to 6.5 psi)
If the pressure is less than specification, check both the intake
air and exhaust systems for leakage.
If there is no leakage, check if the actuator hose has discon-
nected. If not, check the turbocharger.
If the pressure is greater than the specification, check if the ac-
tuator hose has disconnected or cracked. If not, check the
turbocharger.
4. INSPECT TURBO PRESSURE SENSOR
(a) Inspect the power source voltage.
(1) Disconnect the turbo pressure sensor connector.
(2) Turn the ignition switch to ON.
(3) Using a voltmeter, measure the voltage between
connector terminals 3 (VC) and 1 (E2) of the wire
harness side.
Voltage: 4.5 to 5.5 V
If the result is not as specified, check the wiring and ECM.

A87890
PIM (+)
E2 (−) ECM Connector
Vacuum SST
E13 E12
A77125
SST
Pressure
− INTAKETURBO CHARGER SYSTEM (1CD−FTV)(From
September, 2003)13−7
AVENSIS Supplement (RM1045E)
(4) Turn the ignition switch to OFF.
(5) Reconnect the turbo pressure sensor connector.
(b) Inspect the supply power.
(1) Turn the ignition switch to ON.
(2) Disconnect the vacuum hose from the turbo pres-
sure sensor.
(3) Connect a voltmeter to terminals E12−28 (PIM) and
E13−28 (E2) of the ECM, then measure the output
voltage under atmospheric pressure.
(4) Apply vacuum to the turbo pressure sensor in 13.3
kPa (100 mmHg, 3.94 in.Hg) to 66.7 kPa (500
mmHg, 19.69 in.Hg).
(5) Measure the voltage decrease from step (3).
Voltage drop:
Apply Vacuum
[kPa (mmHg, in.Hg)]Voltage Decrease
[V]
13.3 (100, 3.94)0.1 to 0.3
26.7 (200, 7.87)0.3 to 0.5
40.0 (300, 11.81)0.5 to 0.7
57.3 (400, 15.75)0.7 to 0.9
66.7 (500, 19.69)0.9 to 1.0
(6) Using SST (a turbocharger pressure gauge), apply
pressure to the turbo pressure sensor in 19.6 kPa
(0.20 kgf/cm
2, 2.84 psi) to 98.0 kPa (1.00 kgf/cm2,
14.2 psi).
SST 09992−00242
(7) Measure the voltage increase from step (3).
Voltage up:
Applied Pressure
[kPa (kgf/cm2, psi)]
Voltage Increase
[V]
19.6 (0.20, 2.84)0.1 to 0.4
39.2 (0.40, 5.69)0.4 to 0.7
58.8 (0.60, 8.53)0.7 to 1.0
78.5 (0.80, 11.4)1.0 to 1.3
98.0 (1.00, 14.2)1.3 to 1.6
If the result is not as specified, check the wiring and ECM.

1302Y−04
A77119
A77120
A77121
13−4− INTAKETURBO CHARGER SYSTEM (1CD−FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
TURBO CHARGER SYSTEM (1CD−FTV)(From September,
2003)
PRECAUTION
1. MAINTENANCE PRECAUTION
(a) Do not stop the engine immediately after pulling a trailer,
or after high speed or uphill driving. Let the engine idle for
20 to 120 seconds before turning the ignition switch to
OFF (according as the driving condition, the idling time
varies).
(b) Avoid quickly accelerating the pedal or increasing the en-
gine speed immediately after starting a cold engine.
(c) If the turbocharger is found defective, it must be replaced.
Also, inspect the source of the trouble including condi-
tions of the turbocharger that having been used. Repair
or replace the followings if necessary:
(1) Engine oil (level and quality)
(2) Oil lines leading to the turbocharger
(d) Pay due attention when removing and reinstalling the
turbocharger assembly. Do not drop, grasp, or give shock
to the easily−deformed assembly parts such as the actua-
tor or push rod when removing or reinstalling.
(e) Before removing, cover both the intake and exhaust ports
and the oil inlet to prevent dirt or foreign objects from be-
ing introduced.
(f) If replacing the turbocharger, check the oil pipe for depos-
its. If necessary, replace the oil pipe, too.
(g) Thoroughly remove old gasket sticking to the lubrication
oil pipe flange and turbocharger oil flange.
(h) If replacing the bolt(s) or nut(s), Toyota genuine parts
must be used to prevent breakage or deformation.
(i) If replacing the turbocharger, put 20 cm
3(1.2 cu in.) of
fresh oil into the turbocharger oil inlet hole, then turn the
turbine wheel by hand to spread oil to the bearing.
(j) If overhauling or replacing the engine, cut the fuel supply
after reassembling and crank the engine for 30 seconds
to feed oil throughout the engine. Run the engine at idle
for 60 seconds.

A77122
− INTAKETURBO CHARGER SYSTEM (1CD−FTV)(From
September, 2003)13−5
AVENSIS Supplement (RM1045E)
(k) Since the turbine wheels run at extremely high speed, if
the engine is running without the air cleaner, case cover
and hose, the turbine wheel will be damaged by
introduced foreign particles.