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Automatic Transaxle Assembly: Installation

  1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY 

    HINT:

    See INSPECTION  .

    Fig 1: Identifying Torque Converter Clutch Assembly
    G05405961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
    1. Engage the splines of the input shaft and turbine runner.
      Fig 2: Identifying Splines Of Input Shaft And Turbine Runner
      G05405962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.

      HINT:

      If the stator shaft splines are difficult to engage with the stator splines, move the torque converter back approximately 10 mm (0.40 in.) and engage the splines while rotating the torque converter.

      Fig 3: Identifying Splines Of Stator Shaft And Stator
      G05405963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the torque converter clutch assembly to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly.
      Fig 4: Identifying Torque Converter Clutch Assembly
      G05405964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a vernier caliper and a straightedge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (#).
      Fig 5: Measuring Dimension "A" Between Transaxle Fitting Part
      G04976741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a vernier caliper and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (#)).

      Standard: 

      A + 1 mm (0.04 in.) or more 

      NOTE:
      • Make sure to deduct the thickness of the straightedge.
      • If the transaxle is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.

      HINT:

      The standard installation depth is 14 mm (0.55 in.) or more.

      Fig 6: Measuring Dimension Of "B" Transaxle
      G05405966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 OIL COOLER INLET HOSE 
    1. Install the No. 1 oil cooler inlet hose.
      Fig 7: Identifying No. 1 Oil Cooler Inlet Hose
      G04976740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 1 OIL COOLER OUTLET HOSE 
    1. Install the No. 1 oil cooler outlet hose.
      Fig 8: Identifying No. 1 Oil Cooler Outlet Hose
      G04976739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 1 transmission control cable bracket with the 2 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Fig 9: Locating No. 1 Transmission Control Cable Bracket Bolts
      G04976738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the 4 clamp brackets and 4 bolts.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

  7. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF, and install it to the hole cover.
      Fig 10: Identifying Clamp Brackets Bolts
      G04976737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hole cover to the transaxle case with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 11: Identifying O-ring To Hole Cover
      G04976027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL TCM 
    1. Install the TCM to the automatic transaxle assembly.
    2. Install and tighten the 2 bolts in the order shown in the illustration.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Fig 12: Identifying TCM
      G04976751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL ENGINE MOUNTING FRONT BRACKET 
    1. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      Fig 13: Locating Engine Mounting Front Bracket Bolts
      G04976734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Install the automatic transaxle to the engine with the 11 bolts.

      Torque: Bolt A 

      64 N*m (653 kgf*cm, 47 ft.*lbf) 

      Bolt B 

      64 N*m (653 kgf*cm, 47 ft.*lbf) 

      Bolt C 

      46 N*m (469 kgf*cm, 34 ft.*lbf) 

      Bolt D 

      43 N*m (439 kgf*cm, 32 ft.*lbf) 

      NOTE: Make sure that the 2 knock pins are installed on the engine before installing the transaxle.
      Fig 14: Locating Automatic Transaxle Bolts
      G05405974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the breather bracket to the camshaft housing sub-assembly LH with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

    3. Install the breather hose to the breather bracket.
      Fig 15: Locating Breather Bracket Bolt
      G04976731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT CONNECTOR 
    1. Connect the park/neutral position switch connector.
      Fig 16: Locating Park/Neutral Position Switch Connector
      G04976728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WIRE HARNESS 
    1. Connect the wire harness with the bolt.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

  13. INSTALL ENGINE WIRE 
  14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  16. INSTALL FRONT FRAME ASSEMBLY  (See INSTALLATION )
    Fig 17: Locating Wire Harness Bolt
    G04976727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL VANE PUMP ASSEMBLY  (See INSTALLATION )
  18. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE  (See INSTALLATION )
  19. INSTALL COOLER COMPRESSOR ASSEMBLY  (See INSTALLATION )
  20. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  21. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY  (See INSTALLATION )
  22. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.

      Sealant: 

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    2. Install the 6 torque converter clutch mounting bolts.

      Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) 

      NOTE: First install the black colored bolt, and then the remaining 5 bolts.
      Fig 18: Identifying Crankshaft Pulley Bolt
      G04976730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

  24. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET  (See INSTALLATION )
  25. INSTALL FRONT AXLE ASSEMBLY LH  (See INSTALLATION )
  26. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Use the same procedures as described for the LH side.

    Fig 19: Locating Flywheel Housing Under Cover Bolts
    G04976729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See INSTALLATION )
  28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Use the same procedures as described for the LH side.

  29. INSTALL TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  30. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Use the same procedures as described for the LH side.

  31. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  32. INSTALL FRONT SPEED SENSOR RH 

    HINT:

    Use the same procedures as described for the LH side.

  33. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  34. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Use the same procedures as described for the LH side.

  35. INSTALL FRONT AXLE SHAFT LH NUT  (See INSTALLATION )
  36. INSTALL FRONT AXLE SHAFT RH NUT 

    HINT:

    Use the same procedures as described for the LH side.

  37. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  38. INSTALL FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET  (See INSTALLATION )
  39. CONNECT STEERING GEAR OUTLET RETURN TUBE  (See INSTALLATION )
  40. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE  (See INSTALLATION )
  41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install the transmission control cable assembly to the control shaft lever with the nut.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

      Fig 20: Locating Control Shaft Lever Nut
      G04976659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the transmission control cable assembly with a new clip to the No. 1 transmission control cable bracket.
  42. CONNECT ENGINE WIRE  (See INSTALLATION )
  43. INSTALL UPPER RELAY BLOCK COVER 
  44. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  45. INSTALL ECM  (See INSTALLATION )
  46. CONNECT HEATER WATER OUTLET HOSE A  (See INSTALLATION )
    Fig 21: Locating Transmission Cable Bracket Clip
    G05405853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. CONNECT HEATER WATER INLET HOSE A  (See INSTALLATION )
  48. CONNECT NO. 1 OIL COOLER OUTLET HOSE  (See INSTALLATION )
  49. CONNECT NO. 1 OIL COOLER INLET HOSE  (See INSTALLATION )
  50. INSTALL RADIATOR HOSE OUTLET  (See INSTALLATION )
  51. INSTALL RADIATOR HOSE INLET  (See INSTALLATION )
  52. CONNECT FUEL TUBE SUB-ASSEMBLY  (See INSTALLATION )
  53. INSTALL INTAKE AIR SURGE TANK ASSEMBLY  (See INSTALLATION )
  54. CONNECT NO. 1 FUEL VAPOR FEED HOSE  (See INSTALLATION )
  55. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY  (See INSTALLATION )
  56. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  57. INSTALL AIR CLEANER CASE  (See INSTALLATION )
  58. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  (See INSTALLATION )
  59. INSTALL NO. 2 AIR CLEANER INLET  (See INSTALLATION )
  60. CONNECT VACUUM HOSES  (See INSTALLATION )
  61. INSTALL ENGINE MOVING CONTROL ROD  (See INSTALLATION )
  62. INSTALL NO. 2 ENGINE MOUNTING STAY RH  (See INSTALLATION )
  63. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
  64. INSTALL V-RIBBED BELT  (See INSTALLATION )
  65. INSTALL BATTERY 
  66. INSTALL COWL TOP PANEL OUTER 
  67. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  68. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  69. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  70. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  71. INSTALL FRONT WHEELS  (See INSTALLATION )
  72. ADD ENGINE COOLANT  (See REPLACEMENT )
  73. ADD POWER STEERING FLUID 
  74. BLEED POWER STEERING SYSTEM  (See ON-VEHICLE INSPECTION )
  75. ADD AUTOMATIC TRANSAXLE FLUID 

    HINT:

    See ADJUSTMENT  .

  76. INSPECT SHIFT LEVER POSITION  (See ADJUSTMENT  )
  77. ADJUST SHIFT LEVER POSITION  (See ADJUSTMENT  )
  78. INSPECT FOR ENGINE COOLANT LEAK  (See REPLACEMENT )
  79. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  80. INSPECT FOR EXHAUST GAS LEAK 
  81. INSPECT IGNITION TIMING  (See ON-VEHICLE INSPECTION )
  82. INSPECT ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION )
  83. CHECK FUNCTION OF THROTTLE BODY  (See ON-VEHICLE INSPECTION )
  84. INSTALL V - BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  85. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  86. INSPECT CO/HC  (See ON-VEHICLE INSPECTION )
  87. INSPECT ABS SPEED SENSOR SIGNAL 
    1. VSC: See TEST MODE PROCEDURE .
  88. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    HINT:

    See ADJUSTMENT .

  89. INSTALL FRONT FENDER APRON SEAL RH 
  90. INSTALL ENGINE UNDER COVER LH 
  91. INSTALL ENGINE UNDER COVER RH 
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