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Automatic Transaxle Assembly: Installation

  1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
    1. Install the torque converter clutch to the automatic transaxle.
    2. 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. (#)
      NOTE: Subtract the thickness of the straightedge from the measured value to gain dimension A.
      Fig 1: Measuring Dimension A Between Transaxle Fitting Surface Of Engine And Torque Converter Fitting Surface
      G06032140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set the key at the top of the front oil pump drive gear and put a mark on the housing.
      Fig 2: Setting Key At Top Of Front Oil Pump Drive Gear And Put Mark On Housing
      G06116269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Put a mark on the torque converter so that its groove is clearly indicated.
      Fig 3: Identifying Mark On Torque Converter
      G06116270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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.
      Fig 4: Aligning Matchmark On Case With Torque Converter
      G06116271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. After rotating the torque converter, fit the splines of the stator shaft with the stator splines.

      HINT:

      Rotate the torque converter approximately 180 degrees.

      Fig 5: Identifying Matchmark On Torque Converter
      G06116272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. 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.
      NOTE: Do not push the torque converter excessively when rotating it.
      Fig 6: Aligning Mark On Case With Torque Converter And Key
      G06116273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. 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 

      NOTE: Make sure to deduct the thickness of the straightedge.
      Fig 7: Measuring Dimension B
      G06116274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Install the automatic transaxle to the engine with the 10 bolts.

      Torque: Bolt A 

      64 N*m (650 kgf*cm, 47 ft.*lbf) 

      Bolt B 

      46 N*m (470 kgf*cm, 34 ft.*lbf) 

      Bolt C 

      43 N*m (438 kgf*cm, 32 ft.*lbf) 

      NOTE: Confirm that 2 knock pins are on the transaxle fitted surface of the engine block before the transaxle installation.
      Fig 8: Locating Automatic Transaxle With Bolts
      G05000664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 

      Fig 9: Applying Drops Of Adhesive Of Torque Converter Clutch Mounting Bolts
      G04828778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 6 torque converter clutch mounting bolts.

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

      NOTE: First install the different colored bolt, and then the remaining 5 bolts.
      Fig 10: Locating Torque Converter Clutch Mounting Bolts
      G05000656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  3. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the transmission oil filler tube sub-assembly.
      Fig 11: Identifying Flywheel Housing Bolts
      G05246734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt.

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

  4. INSTALL NO. 1 OIL COOLER INLET TUBE 
    1. Temporarily install the No. 1 oil cooler outlet tube.
    2. Temporarily install the No. 1 oil cooler inlet tube.
      Fig 12: Locating Transmission Oil Filter Tube Bolt
      G05268811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil cooler tube clamp with the bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      HINT:

      Install them so that the oil cooler tube cushion is positioned as shown in the illustration.

      Fig 13: Locating Oil Cooler Tube Clamp
      G05268810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a union nut wrench (17 mm), install the No. 1 oil cooler inlet tube while holding the union with a wrench.

      Torque: Without a union nut wrench 

      34 N*m (347 kgf*cm, 25 ft.*lbf) 

      With a union nut wrench 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      NOTE:
      • 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.
        Fig 14: Identifying Torque Wrench Fulcrum Length
        G06116281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 OIL COOLER OUTLET TUBE 
    1. Using a union nut wrench, install the No. 1 oil cooler outlet tube while holding the union with a wrench.

      Torque: Without a union nut wrench 

      34 N*m (347 kgf*cm, 25 ft.*lbf) 

      With a union nut wrench 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      NOTE:
      • 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.
        Fig 15: Installing No. 1 Oil Cooler Outlet Tube
        G06116282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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 16: Locating No. 1 Transmission Control Cable Bracket
      G05268807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT BREATHER PLUG HOSE 
    1. Connect the breather plug hose to the oil filler tube.
      Fig 17: Identifying Breather Plug Hose
      G05268805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT CONNECTORS 
    1. Connect the transmission wire connector.
    2. Connect the park/neutral position switch connector.
    3. Connect the 2 speed sensor connectors.
      Fig 18: Identifying Transmission Wire And Park/Neutral Position Switch Connector
      G05415730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT WIRE HARNESS 
    1. Connect the wire harness with the bolt.

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

      Fig 19: Locating Wire Harness Bolt
      G05415728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL WIRE HARNESS CLAMP 
    1. Install the 3 clamps and 3 bolts.

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

    2. Connect the wire harness with the bolt.

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

      Fig 20: Locating Wire Harness Clamp With Bolts
      G05415727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 2 transmission control cable bracket with the bolt.

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

  12. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  13. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)  (See INSTALLATION )
    Fig 21: Locating Transmission Control Cable Bracket Bolt
    G05246724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET  (See INSTALLATION )
  15. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY  (See INSTALLATION )
  16. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR  (See INSTALLATION )
  17. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR  (See INSTALLATION )
  18. INSTALL FRONT FRAME ASSEMBLY  (See INSTALLATION )
  19. INSTALL POWER STEERING LINK ASSEMBLY  (See INSTALLATION )
  20. INSTALL FRONT STABILIZER BAR  (See INSTALLATION )
  21. REMOVE ENGINE HANGERS  (See INSTALLATION )
  22. INSTALL MANIFOLD STAY  (See INSTALLATION )
  23. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  24. INSTALL ENGINE WIRE (for LHD)  (See INSTALLATION )
  25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY  (See INSTALLATION )
  26. INSTALL VENTILATION HOSE  (See INSTALLATION )
  27. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH  (See INSTALLATION )
  28. INSTALL COMPRESSOR AND MAGNETIC CLUTCH  (See INSTALLATION )
  29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE  (See INSTALLATION )
  30. CONNECT SUCTION HOSE SUB-ASSEMBLY  (See INSTALLATION )
  31. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  32. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See INSTALLATION )
  33. INSTALL FRONT AXLE ASSEMBLY LH  (See INSTALLATION )
  34. INSTALL FRONT AXLE ASSEMBLY RH  (See INSTALLATION )
  35. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM LH  (See INSTALLATION )
  36. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM RH  (See INSTALLATION )
  37. CONNECT TIE ROD ASSEMBLY LH  (See INSTALLATION )
  38. CONNECT TIE ROD ASSEMBLY RH  (See INSTALLATION )
  39. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  40. INSTALL FRONT SPEED SENSOR RH  (See INSTALLATION )
  41. INSTALL FRONT AXLE HUB NUT LH  (See INSTALLATION )
  42. INSTALL FRONT AXLE HUB NUT RH  (See INSTALLATION )
  43. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  44. INSTALL FRONT STABILIZER LINK ASSEMBLY RH  (See INSTALLATION )
  45. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  46. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY  (See INSTALLATION )
  47. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  48. INSTALL TAIL EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  49. CONNECT ENGINE WIRE  (See INSTALLATION )
  50. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY  (See INSTALLATION )
  51. CONNECT FUEL TUBE SUB-ASSEMBLY  (See INSTALLATION )
  52. CONNECT OIL COOLER OUTLET HOSE  (See INSTALLATION )
  53. CONNECT OIL COOLER INLET HOSE  (See INSTALLATION )
  54. CONNECT HEATER WATER HOSE INLET B  (See INSTALLATION )
  55. CONNECT HEATER WATER HOSE OUTLET B  (See INSTALLATION )
  56. INSTALL NO. 1 RADIATOR HOSE  (See INSTALLATION )
  57. INSTALL NO. 2 RADIATOR HOSE  (See INSTALLATION )
  58. CONNECT UNION TO CHECK VALVE HOSE  (See INSTALLATION )
  59. CONNECT NO. 1 FUEL VAPOR FEED HOSE  (See INSTALLATION )
  60. INSTALL ENGINE MOVING CONTROL ROD  (See INSTALLATION )
  61. INSTALL NO. 2 ENGINE MOUNTING STAY RH  (See INSTALLATION )
  62. INSTALL RESERVOIR BRACKET (for LHD)  (See INSTALLATION )
  63. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD)  (See INSTALLATION )
  64. INSTALL AIR CLEANER BRACKET  (See INSTALLATION )
  65. INSTALL BATTERY  (See 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.
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  67. INSTALL AIR CLEANER CASE SUB-ASSEMBLY  (See ON-VEHICLE INSPECTION )
  68. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY  (See INSTALLATION )
  69. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INTAKE MANIFOLD )
  70. INSTALL NO. 1 AIR CLEANER INLET  (See INTAKE MANIFOLD )
  71. INSTALL NO. 2 AIR CLEANER INLET  (See COMPONENTS )
  72. CONNECT VACUUM HOSES  (See INSTALLATION )
  73. INSTALL V-RIBBED BELT  (See INSTALLATION )
  74. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)  (See INSTALLATION )
  75. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  76. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  77. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  78. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  79. INSTALL FRONT WHEELS  (See INSTALLATION )
  80. ADD ENGINE OIL  (See OIL PRESSURE SWITCH )
  81. ADD ENGINE COOLANT  (See REMOVAL )
  82. ADD AUTOMATIC TRANSAXLE FLUID 
  83. CHECK AUTOMATIC TRANSAXLE FLUID  (See ON-VEHICLE INSPECTION  )
  84. INSPECT FOR FUEL LEAK  (See PARTS LOCATION )
  85. INSPECT FOR ENGINE OIL LEAK  (See OIL PRESSURE SWITCH )
  86. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  87. INSPECT FOR EXHAUST GAS LEAK  (See INSTALLATION )
  88. INSPECT SHIFT LEVER POSITION  (See ON-VEHICLE INSPECTION  )
  89. ADJUST SHIFT LEVER POSITION  (See ADJUSTMENT  )
  90. CHECK AND ADJUST FRONT WHEEL ALIGNMENT  (See INSTALLATION )
  91. CHECK IGNITION TIMING  (See ENGINE )
  92. CHECK ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION )
  93. CHECK CO/HC  (See ON-VEHICLE INSPECTION )
  94. CHECK FUNCTION OF THROTTLE BODY ASSEMBLY  (See INSPECTION PROCEDURE )
  95. INSTALL FRONT FENDER APRON SEAL LH  (See INSTALLATION )
  96. INSTALL FRONT FENDER APRON SEAL RH  (See INSTALLATION )
  97. INSTALL FRONT FENDER LINER LH  (See INSTALLATION )
  98. INSTALL FRONT FENDER LINER RH  (See INSTALLATION )
  99. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH  (See INSTALLATION )
  100. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH  (See INSTALLATION )
  101. INSTALL FLOOR UNDER COVER LH 
  102. INSTALL NO. 2 ENGINE UNDER COVER  (See INSTALLATION )
  103. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  104. INSTALL ENGINE UNDER COVER ASSEMBLY  (See INSTALLATION )
  105. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  106. CHECK ABS SPEED SENSOR SIGNAL  (See INSTALLATION )
  107. RESET MEMORY  (See INSTALLATION )
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