Installation
U151E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Install the torque converter clutch to the automatic transaxle.
(b) Using a vernier caliper and a straightedge, measure dimension A between the transaxle fitting surface of the engine *1 and the torque converter fitting surface of the drive plate *2. (#)
NOTICE:
Subtract the thickness of the straightedge from the measured value to gain dimension A.
(c) Set the key at the top of the front oil pump drive gear and put a mark on the housing.
(d) Put a mark on the torque converter so that its groove is clearly indicated.
(e) Align the matchmark on the case with the one on the torque converter and fit the splines of the input shaft to the turbine runner splines.
(f) After rotating the torque converter, fit the splines of the stator shaft with the stator splines.
HINT
Rotate the torque converter approximately 180 degrees.
(g) After rotating the torque converter again, align the mark on the case with the one on the torque converter and fit the key of the oil pump drive gear into the torque converter keyway.
NOTICE:
Do not push the torque converter excessively when rotating it.
(h) Using a vernier caliper and a straightedge, measure dimension B shown in the illustration and check that dimension B is greater than dimension A (measured in step (#)).
Standard:
A + 1 mm (0.04 in.) or more
NOTICE:
Make sure to deduct the thickness of the straightedge.
2. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle to the engine with the 10 bolts.
Bolt A - Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)
Bolt B - Torque : 46 Nm (470 kgf-cm, 34 ft-lbf)
Bolt C - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
NOTICE:
Confirm that 2 knock pins are on the transaxle fitted surface of the engine block before the transaxle installation.
(b) Apply a few drops of adhesive the first of 2 or 3 threads of the 6 torque converter clutch mounting bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Install the 6 torque converter clutch mounting bolts.
Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)
NOTICE:
First install the different colored bolt, and then the remaining 5 bolts.
(d) Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the transmission oil filler tube sub-assembly.
(b) Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
4. 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 in-lbf)
HINT
Install them so that the oil cooler tube cushion is positioned as shown in the illustration.
(d) Using a union nut wrench (17 mm), install the No. 1 oil cooler inlet tube while holding the union with a wrench.
Without a union nut wrench - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)
With a union nut wrench - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)
NOTICE:
* Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.
5. INSTALL NO. 1 OIL COOLER OUTLET TUBE
(a) Using a union nut wrench, install the No. 1 oil cooler outlet tube while holding the union with a wrench.
Without a union nut wrench - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)
With a union nut wrench - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)
NOTICE:
* Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
* This torque value is effective the when union nut wrench is parallel to the torque wrench.
6. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET
(a) Install the No. 1 transmission control cable bracket with the 2 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
7. CONNECT BREATHER PLUG HOSE
(a) Connect the breather plug hose to the oil filler tube.
8. CONNECT CONNECTORS
(a) Connect the transmission wire connector.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 speed sensor connectors.
9. CONNECT WIRE HARNESS
(a) Connect the wire harness with the bolt.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
10. INSTALL WIRE HARNESS CLAMP
(a) Install the 3 clamps and 3 bolts.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(b) Connect the wire harness with the bolt.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
11. 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-lbf)
12. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
13. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Installation
14. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET Installation
15. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Installation
16. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR Installation
17. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR Installation
18. INSTALL FRONT FRAME ASSEMBLY Installation
19. INSTALL POWER STEERING LINK ASSEMBLY Installation
20. INSTALL FRONT STABILIZER BAR Installation
21. REMOVE ENGINE HANGERS Installation
22. INSTALL MANIFOLD STAY Installation
23. INSTALL STARTER ASSEMBLY Installation
24. INSTALL ENGINE WIRE (for LHD) Installation
25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation
26. INSTALL VENTILATION HOSE Installation
27. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Installation
28. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation
29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation
30. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation
31. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation
32. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation
33. INSTALL FRONT AXLE ASSEMBLY LH Installation
34. INSTALL FRONT AXLE ASSEMBLY RH Installation
35. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM LH Installation
36. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM RH Installation
37. CONNECT TIE ROD ASSEMBLY LH Installation
38. CONNECT TIE ROD ASSEMBLY RH Installation
39. INSTALL FRONT SPEED SENSOR LH Installation
40. INSTALL FRONT SPEED SENSOR RH Installation
41. INSTALL FRONT AXLE HUB NUT LH Installation
42. INSTALL FRONT AXLE HUB NUT RH Installation
43. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
44. INSTALL FRONT STABILIZER LINK ASSEMBLY RH Installation
45. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
46. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation
47. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation
48. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation
49. CONNECT ENGINE WIRE Installation
50. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation
51. CONNECT FUEL TUBE SUB-ASSEMBLY Installation
52. CONNECT OIL COOLER OUTLET HOSE Installation
53. CONNECT OIL COOLER INLET HOSE Installation
54. CONNECT HEATER WATER HOSE INLET B Installation
55. CONNECT HEATER WATER HOSE OUTLET B Installation
56. INSTALL NO. 1 RADIATOR HOSE Installation
57. INSTALL NO. 2 RADIATOR HOSE Installation
58. CONNECT UNION TO CHECK VALVE HOSE Installation
59. CONNECT NO. 1 FUEL VAPOR FEED HOSE Installation
60. INSTALL ENGINE MOVING CONTROL ROD Installation
61. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation
62. INSTALL RESERVOIR BRACKET (for LHD) Installation
63. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD) Installation
64. INSTALL AIR CLEANER BRACKET Installation
65. INSTALL BATTERY Installation
66. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
67. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
68. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Installation
69. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
70. INSTALL NO. 1 AIR CLEANER INLET Installation
71. INSTALL NO. 2 AIR CLEANER INLET Installation
72. CONNECT VACUUM HOSES Installation
73. INSTALL V-RIBBED BELT Installation
74. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD) Installation
75. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
76. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
77. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
78. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
79. INSTALL FRONT WHEELS Installation
80. ADD ENGINE OIL Replacement
81. ADD ENGINE COOLANT Service and Repair
82. ADD AUTOMATIC TRANSAXLE FLUID
83. CHECK AUTOMATIC TRANSAXLE FLUID Procedures
84. INSPECT FOR FUEL LEAK Fuel System
85. INSPECT FOR ENGINE OIL LEAK Replacement
86. INSPECT FOR COOLANT LEAK Testing and Inspection
87. INSPECT FOR EXHAUST GAS LEAK Installation
88. INSPECT SHIFT LEVER POSITION On-Vehicle Inspection
89. ADJUST SHIFT LEVER POSITION Adjustments
90. CHECK AND ADJUST FRONT WHEEL ALIGNMENT Installation
91. CHECK IGNITION TIMING Engine
92. CHECK ENGINE IDLE SPEED Engine
93. CHECK CO/HC Engine
94. CHECK FUNCTION OF THROTTLE BODY ASSEMBLY On-Vehicle Inspection
95. INSTALL FRONT FENDER APRON SEAL LH Installation
96. INSTALL FRONT FENDER APRON SEAL RH Installation
97. INSTALL FRONT FENDER LINER LH Installation
98. INSTALL FRONT FENDER LINER RH Installation
99. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH Installation
100. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH Installation
101. INSTALL FLOOR UNDER COVER LH
102. INSTALL NO. 2 ENGINE UNDER COVER Installation
103. INSTALL NO. 1 ENGINE UNDER COVER Installation
104. INSTALL ENGINE UNDER COVER ASSEMBLY Installation
105. INSTALL V-BANK COVER SUB-ASSEMBLY Installation
106. CHECK ABS SPEED SENSOR SIGNAL Installation
107. RESET MEMORY Installation