engine TOYOTA SIENNA 2007 Service Repair Manual

AX–16U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
(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
position, depress the accelerator pedal all the
way down and check the line pressure while the
stall test is performed.
Specified line pressure:
(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 engine.
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 idling and during the stall test.
Specified line pressure:
(16)Remove the SST, install the test plug B.
(17)Clear the DTC.
Evaluation:
C160154E01
Condition
D position kPa (kgf / cm2, psi)
Stall test931 to 1,031 kPa
(9.5 to 10.5 kgf/cm
2, 135 to 150 psi)
Condition
R position kPa (kgf / cm
2, psi)
Idling672 to 742 kPa
(6.9 to 7.6 kgf/cm
2, 97 to 108 psi)
Stall test1,768 to 1,968 kPa
(18.0 to 20.1 kgf/cm
2, 256 to 285 psi)
Problem Possible cause
Measured values are higher than specified in all positions• Shift solenoid valve SLT defective
• Regulator valve defective
Measured values are lower than specified in all positions• Shift solenoid valve SLT defective
• Regulator valve defective
• Oil pump defective
• U/D (Underdrive) direct clutch defective
Pressure is low in the D position only• D position circuit fluid leak
• Forward clutch defective
Pressure is low in the R position only• R position circuit fluid leak
• Reverse clutch defective
• 1st and reverse brake defective

U151F AUTOMATIC TRANSAXLE – PARK / NEUTRAL POSITION SWITCHAX–127
AX
INSPECTION
1. INSPECT PARK/NEUTRAL POSITION SWITCH
ASSEMBLY OPERATION
(a) Apply the parking brake and turn the ignition switch
to the ON position.
(b) Depress the brake pedal and check that the engine
starts only when the shift lever is in the N or P
position and the engine does not start when the shift
lever is in other positions.
(c) Check that the back up light comes on and the
reverse warning buzzer sounds only when the shift
lever is in the R position and the light and buzzer do
not operate when the shift lever is in other positions.
(d) If a failure is found, check the park/neutral position
switch for continuity.
2. INSPECT PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Jack up the vehicle.
(b) Disconnect the park/neutral position switch
connector.
(c) Measure the resistance according to the value(s) in
the table below when the shift lever is moved to
each position.
Resistance
ADJUSTMENT
1. ADJUST PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Loosen the 2 bolts of the park/neutral position
switch and move the shift lever to the N position.
(b) Align the groove with the neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(d) After adjustment, perform the inspection described
in park/neutral position switch assembly operation.
C110340E10
Shift Position Tester Connection Specified Condition
P
2 - 6 and 4 - 5Below 1
Except P 10 k or higher
R
2 - 1Below 1
Except R 10 k or higher
N
2 - 9 and 4 - 5Below 1
Except N 10 k or higher
D and 4
2 - 7Below 1
Except D and 4 10 k or higher
3
2 - 3Below 1
Except 3 10 k or higher
2 and L
2 - 8Below 1
Except 2 and L 10 k or higher
C099453E01

AX–18U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
INITIALIZATION
1. RESET MEMORY
NOTICE:
• Perform the RESET MEMORY (AT initialization)
when replacing the automatic transaxle assembly,
engine assembly or ECM.
• The RESET MEMORY can be performed only with
the Intelligent tester.
HINT:
The ECM memorizes the condition that the ECT controls
the automatic transaxle assembly and engine assembly
according to those characteristics. Therefore, when the
automatic transaxle assembly, engine assembly, or ECM
has been replaced, it is necessary to reset the memory
so that the ECM can memorize the new information.
Reset procedure is as follows.
(a) Turn the engine switch off.
(b) Connect the intelligent tester together with the CAN
VIM (controller area network vehicle interface
module) to the DLC3.
(c) Turn the ignition switch to the ON position and push
the intelligent tester main switch on.
(d) Select the item "DIAGNOSIS / ENHANCED OBD
II".
(e) Perform the reset memory procedure from the
ENGINE menu.
CAUTION:
After performing the RESET MEMORY, be sure
to perform the ROAD TEST (See page AX-9)
described earlier.
HINT:
The ECM is learned by performing the ROAD TEST.
(1) Tester menu flow:

U151F AUTOMATIC TRANSAXLE – TRANSMISSION WIREAX–131
AX
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE ENGINE UNDER COVER NO.1
3. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain the
AT F.
(b) Install a new gasket and the drain plug.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
4. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Carefully
remove the oil pan so that fluid remaining in the
pan does not spill out.
(b) Remove the 2 magnets from the oil pan.
(c) Examine particles in the pan.
(1) Collect any steel chips using the removed
magnets. Look carefully at the chips and
particles in the pan and on the magnets to see
the type of wear which might be found in the
transaxle.
Result:
Steel (magnetic):
Wear of the bearing, gear or plate
Brass (non-magnetic):
Wear of the bearing
5. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the
ATF temperature sensor.
C091925
D030865
AT00103
C091927E04

U151F AUTOMATIC TRANSAXLE – TRANSMISSION WIREAX–133
AX
(c) Using a new gasket, install the oil pan to the
transaxle case with the 18 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
NOTICE:
Apply seal packing to the bolts and tighten them
within 10 minutes of application.
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
5. ADD AUTOMATIC TRANSAXLE FLUID
6. INSPECT AUTOMATIC TRANSAXLE FLUID (See page
AX-123)
7. INSTALL ENGINE UNDER COVER NO.1
8. RESET MEMORY
HINT:
(See page AX-16)
C091925

AX–20U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
MONITOR DRIVE PATTERN
1. MONITOR DRIVE PATTERN FOR ECT TEST
(a) Perform this drive pattern as one method to
simulate the detection conditions of the ECT
malfunctions. (The DTCs may not be detected due
the actual driving conditions. And some codes may
not be detected through this drive pattern.)
HINT:
Preparation for driving
• Warm up the engine sufficiently. (Engine coolant
temperature is 60
C (140F) or higher)
• Drive the vehicle when the atmospheric
temperature is -10
C (14F) or higher.
(Malfunction is not detected when the
atmospheric temperature is less than -10
C
(14
F))
Driving note
• Drive the vehicle through all gears.
Stop
1st 2nd 3rd 4th 5th 5th
(lock-up ON).
• Repeat the above driving pattern three times or
more.
NOTICE:
• The monitor status can be checked using the
OBD II scan tool or intelligent tester. When
using the intelligent tester, monitor status
can be found in the "ENHANCED OBD II /
DATA LIST" or under "CARB OBD II".
• In the event that the drive pattern must be
interrupted (possibly due to traffic conditions
or other factors), the drive pattern can be
resumed and, in most cases, the monitor can
be completed.
• Perform this drive pattern on a level road as
much as possible and strictly observe the
posted speed limits and traffic laws while
driving.

AX–136U151F AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLY
AX
REMOVAL
1. REMOVE ENGINE UNDER COVER NO.1
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. DRAIN AUTOMATIC TRANSAXLE FLUID (See page
AX-131)
4. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Carefully
remove the oil pan so that the fluid remaining in
the pan does not spill out.
(b) Remove the 2 magnets from the oil pan.
(c) Examine particles in the pan.
(1) Collect any steel chips using the removed
magnets. Look carefully at the chips and
particles in the pan and on the magnets to see
the type of wear which might be found in the
transaxle.
Result:
Steel (magnetic):
Wear of the bearing, gear or plate
Brass (non-magnetic):
Wear of the bearing
5. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the
ATF temperature sensor.
C091925
D030865
AT00103
C091927E04

U151F AUTOMATIC TRANSAXLE – VALVE BODY ASSEMBLYAX–141
AX
(c) Install the oil strainer with the 3 bolts.
Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
3. INSTALL TRANSMISSION WIRE
(a) Coat the O-ring with ATF.
(b) Install the ATF temperature sensor with the lock
plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
(c) Connect the 7 shift solenoid valve connectors.
4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to the 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install the oil pan and new gasket with the 18 bolts
to the transaxle case.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
NOTICE:
Tighten the bolts within 10 minutes of sealant
application.
5. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
6. ADD AUTOMATIC TRANSAXLE FLUID
7. CHECK FLUID LEVEL IN AUTOMATIC TRANSAXLE
(See page AX-123)
8. INSTALL ENGINE UNDER COVER NO.1
9. RESET MEMORY
HINT:
(See page AX-16)
C091931
C091927E04
D030865
C091925

AX–22U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
PROBLEM SYMPTOMS TABLE
HINT:
• If a normal code is displayed during the diagnostic trouble
code check although the trouble still occurs, check the
electrical 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 2 chapters.
• When the circuit on which mark *1 is attached is a
malfunction, DTC could be output.
Refer to the table below when the trouble cause is considered
to be electrical. If the instruction PROCEED TO NEXT
CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS
TABLE is given in the flowchart of each circuit, inspect the
suspected areas in descending order for each symptom. If
the trouble still occurs even though there are no
abnormalities in the inspections listed for the symptoms,
check and replace the ECM.
1. Chapter 1: Electronic Circuit Matrix Chart
Symptom Suspected Area See page
No down-shift (A particular gear, from 1st to 4th gear,
is not down-shifted)ECMIN-30
No down-shift (5th -> 4th)Transmission control switch (D <--> 4 position) circuitAX-38
Shift solenoid valve S4 circuit *1AX-104
ECMIN-30
No up-shift (A particular gear, from 1st to 4th gear, is
not up-shifted)ECMIN-30
No up-shift (4th -> 5th)Transmission control switch (D <--> 4 position) circuitAX-38
Shift solenoid valve S4 circuit *1AX-104
ECMIN-30
No lock-upStop light switch circuit *1AX-56
Engine coolant temp. sensor circuit *1ES-56
ECMIN-30
No lock-up off ECMIN-30
Shift point too high or too lowThrottle position sensor circuit *1ES-56
ECMIN-30
Up-shift to 5th from 4th while shift lever is in 4 positionTransmission control switch (D <--> 4 position) circuitAX-38
ECMIN-30
Up-shift to 5th from 4th while engine is coldEngine coolant temp. sensor circuit *1ES-56
ECMIN-30
Up-shift to 2nd from 1st while shift lever is in L positionTransmission control switch (L <--> 2 position) circuit *1AX-38
ECMIN-30
Harsh engagement (N -> D)Shift solenoid valve SL1 circuit *1AX-70
ECMIN-30
Harsh engagement (Lock-up) ECMIN-30
Harsh engagement (Any driving position) ECMIN-30
Poor acceleration ECMIN-30
No kick-down ECMIN-30
Engine stalls when starting off or stopping ECMIN-30
Malfunction in shiftingPark/neutral position switch circuit *1AX-38
Transmission control switch (D <--> 4 position) circuitAX-38
ECMIN-30

AX–24U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
Harsh engagement (5th -> 4th)Valve body assemblyAX-136
B3 accumulatorAX-181
Slip or shudder (Forward and reverse: After warm-up)Valve body assemblyAX-136
Oil strainerAX-136
Direct and O/D clutch (C0)AX-181
Forward clutch (C1)AX-181
U/D clutch (C3)AX-181
2nd and brake (B1)AX-181
U/D brake (B3)AX-181
No. 1 one-way clutch (F1)AX-181
U/D one-way clutch (F2)AX-181
Torque converter clutchAX-172
Slip or shudder (Particular position: Just after engine
starts)Torque converter clutchAX-172
Slip or shudder (R position)Reverse clutch (C2)AX-181
1st and reverse brake (B2)AX-181
Slip or shudder (1st)Forward clutch (C1)AX-181
No. 1 one-way clutch (F1)AX-181
U/D one-way clutch (F2)AX-181
Slip or shudder (2nd) 2nd and O/D brake (B1)AX-181
Slip or shudder (3rd) Direct and O/D clutch (C0)AX-181
Slip or shudder (4th) 2nd and O/D brake (B1)AX-181
Slip or shudder (5th) U/D clutch (C3)AX-181
Shift position too high or too low Shift solenoid valve SLTAX-116
No engine braking (1st +- 4th: D position) U/D brake (B3)AX-181
No engine braking (1st: L (1) position)Valve body assemblyAX-136
1st and reverse brake (B2)AX-181
No engine braking (2nd: 2 position)Valve body assemblyAX-136
2nd and O/D brake (B1)AX-181
No engine braking (3rd: 3 position) U/D brake (B3)AX-181
No kick-down Valve body assemblyAX-136
Poor acceleration (All positions)Shift solenoid valve SLTAX-116
Torque converter clutchAX-172
Poor acceleration (5th)U/D clutch (C3)AX-181
U/D planetary gear unitAX-181
Engine stalls when starting off or stoppingShift solenoid valve DSLAX-60
Torque converter clutchAX-172 Symptom Suspected Area See page