Installation

AUTOMATIC TRANSAXLE ASSEMBLY

INSTALLATION

1. INSTALL TRANSAXLE CASE UPPER COVER
(a) Install the transmission case upper cover with the 3 bolts.
Torque: 12 Nm (117 kgf-cm, 8 ft. lbs.)

2. INSTALL ENGINE MOUNTING FRONT BRACKET
(a) Install the engine mounting front bracket to the automatic transaxle with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

3. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the oil filler tube.

(b) Install the oil filler tube to the automatic transaxle with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.)
(c) Install the ATF level gauge.

4. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET
(a) Install the No. 1 control cable bracket with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)

5. INSTALL NO. 1 OIL COOLER INLET TUBE
(a) Temporarily install the No. 1 oil cooler outlet tube.
(b) Temporarily install the No. 1 oil cooler inlet tube.

(c) Install the oil cooler tube clamp with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

HINT: Install the oil cooler tube clamp so that the oil cooler tube cushions are positioned as shown in the illustration.

(d) Using SST and a wrench, tighten the No. 1 oil cooler inlet tube.
SST 09023-12701
Torque: For use without SST 34 Nm (350 kgf-cm, 25 ft. lbs.)
For use with SST 32 Nm (322 kgf-cm, 24 ft. lbs.)

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

6. INSTALL NO. 1 OIL COOLER OUTLET TUBE
(a) Using SST and a wrench, tighten the No. 1 oil cooler outlet tube.
SST 09023-12701
Torque:
For use without SST 34 Nm (350 kgf-cm, 25 ft. lbs.)
For use with SST 32 Nm (322 kgf-cm, 24 ft. lbs.)

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

7. CONNECT CONNECTORS
(a) Connect the transmission wire connector.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 speed sensor connectors.

8. CONNECT WIRE HARNESS
(a) Connect the wire harness with the bolt.
Torque: 12 Nm (130 kgf-cm, 9 ft. lbs.)

9. INSTALL WIRE HARNESS CLAMP BRACKET
(a) Install the 2 brackets with the 2 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
(b) Connect the wire harnesses to the clamps.

10. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET
(a) Install the No. 2 transmission control cable bracket with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)

11. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUBASSEMBLY
(a) Coat a new O-ring with ATF WS, and install it to the hole cover.

(b) Install the hole cover to the transaxle case with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 47 inch lbs.)

12. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Using vernier calipers and a straight edge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (#1).

(b) Set the key of the front oil pump drive gear to the top and put a mark on the housing.

(d) Align the 2 marks on the transaxle case and torque converter clutch and fit the splined part of the input shaft to the spline part of the turbine runner.

(e) Rotating the torque converter clutch, fit the spline part of the stator shaft to the spline part of the stator.

HINT: Rotate it about 180°.

(f) Rotating the torque converter clutch, align the 2 marks on the case and the torque converter clutch again and fit the key of the oil pump drive gear into the key way of the torque converter clutch.

CAUTION: When rotating the torque converter clutch, do not push it with excessive force.

(g) Using vernier calipers and a straight edge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (#1)).
Standard: A + 1 (0.04 inch) mm or more

NOTICE: Remember to minus the thickness of the straight edge.

13. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle to the engine with the 5 bolts.
Torque:
Bolt A 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B 46 Nm (469 kgf-cm, 34 ft. lbs.)
Bolt C 46 Nm (469 kgf-cm, 34 ft. lbs.)

(b) Install the 4 lower side mounting bolts.
Torque: Bolt D 44 Nm (449 kgf-cm, 32 ft. lbs.)

14. INSTALL STARTER ASSEMBLY
15. INSTALL ENGINE WIRE
16. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
17. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
18. INSTALL FRONT FRAME ASSEMBLY
19. INSTALL VANE PUMP ASSEMBLY
20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
21. INSTALL STEERING SLIDING YOKE
22. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
(a) Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent.

(b) Install the 6 torque converter clutch mounting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)

NOTICE: First install the black colored bolt, and then the remaining 5 bolts.

(c) Install the flywheel housing under cover.

23. INSTALL FRONT AXLE ASSEMBLY LH
24. INSTALL FRONT AXLE ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

25. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH
26. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH

HINT: Use the same procedures described for the LH side.

27. INSTALL TIE ROD ASSEMBLY LH
28. INSTALL TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

29. INSTALL FRONT SPEED SENSOR LH
30. INSTALL FRONT SPEED SENSOR RH

HINT: Use the same procedures described for the LH side.

31. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
32. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

33. INSTALL FRONT AXLE HUB NUT LH
34. INSTALL FRONT AXLE HUB NUT RH

HINT: Use the same procedures described for the LH side.

35. INSTALL FRONT EXHAUST PIPE ASSEMBLY
36. CONNECT COMPRESSOR AND MAGNETIC CLUTCH
37. INSTALL GENERATOR ASSEMBLY
38. CONNECT FUEL TUBE SUBASSEMBLY
39. CONNECT RETURN TUBE SUBASSEMBLY
40. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Connect the transmission control cable assembly to the control cable clamp.

(b) Connect the transmission control cable to the bracket with a new clip.

(c) Connect the transmission control cable assembly to the control shaft lever with the nut.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)

42. CONNECT ENGINE WIRE
43. INSTALL ECM
44. CONNECT HEATER INLET WATER HOSE
45. CONNECT HEATER OUTLET WATER HOSE
46. CONNECT OIL COOLER INLET HOSE
47. CONNECT OIL COOLER OUTLET HOSE
48. CONNECT RADIATOR HOSE INLET
49. CONNECT RADIATOR HOSE OUTLET
50. CONNECT NO. 1 VACUUM HOSE CONNECTOR
51. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
52. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY
53. INSTALL NO. 2 ENGINE MOUNTING STAY RH
54. INSTALL BATTERY
55. INSTALL AIR CLEANER CASE SUBASSEMBLY
56. INSTALL AIR CLEANER CAP SUBASSEMBLY
57. INSTALL AIR CLEANER INLET ASSEMBLY
58. INSTALL V-RIBBED BELT
59. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY
60. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
61. INSTALL FRONT WHEEL
62. ADD ENGINE OIL
63. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
64. ADD ENGINE COOLANT
65. ADD AUTOMATIC TRANSAXLE FLUID
Fluid type: Toyota Genuine ATF WS

66. ADD POWER STEERING FLUID
67. BLEED POWER STEERING FLUID
68. INSPECT AUTOMATIC TRANSAXLE FLUID
69. CHECK FOR FUEL LEAKS
70. CHECK FOR ENGINE OIL LEAKS
71. CHECK FOR ENGINE COOLANT LEAKS
72. CHECK FOR EXHAUST GAS LEAKS
73. CHECK FOR SHIFT LEVER POSITION
74. ADJUST SHIFT LEVER POSITION
75. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
76. CHECK IGNITION TIMING
77. CHECK ENGINE IDLE SPEED
78. INSPECT CO/HC
79. INSTALL FRONT FENDER APRON SEAL RH
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. INSTALL NO. 1 ENGINE COVER SUBASSEMBLY
83. CHECK ABS SPEED SENSOR SIGNAL