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Home >> Toyota >> 2016 >> Avalon XLE Plus >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission (U660E) (Service Information) (Except Hybrid) >> AUTOMATIC TRANSAXLE ASSEMBLY (When Using the Engine Support Bridge) >> Installation [10/2014 - ] >> Procedure

Installation [10/2014 - ]: Procedure

  1. INSTALL TORQUE CONVERTER ASSEMBLY 
    1. Engage the splines of the input shaft and turbine runner.
      GTY110623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the splines of the stator shaft and the stator while turning the torque converter assembly.
      GTY110624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If the stator shaft splines are difficult to engage with the stator splines, move the torque converter assembly back approximately 10 mm (0.394 in.) and engage the splines while rotating the torque converter assembly.

    3. Turn the torque converter assembly to insert the key of the oil pump drive gear into the groove of the torque converter assembly.
      GTY110625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Clean the torque converter assembly set bolt holes.
    5. Using a vernier caliper and straightedge, measure dimension (A) between the transaxle contact surface of the engine and the torque converter assembly contact surface of the drive plate.
      GTY593228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Engine Surface
      *b Drive Plate Surface
      NOTE:

      Make sure to deduct the thickness of the straightedge.

    6. Using a vernier caliper and straightedge, measure dimension (B) shown in the illustration and check that dimension (B) is more than dimension (A), which was measured in the previous step.
      GTY127347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard

      Dimension (A) + 1 mm (0.0394 in.) or more

      NOTE:
      • Make sure to deduct the thickness of the straightedge.
      • If the automatic transaxle assembly is installed to the engine with the torque converter assembly not sufficiently inserted, the torque converter assembly may be damaged.
  2. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSEMBLY 
    1. Apply ATF to a new O-ring and install it to the speedometer driven hole (ATM) cover sub-assembly.
    2. Install the speedometer driven hole (ATM) cover sub-assembly to the automatic transaxle assembly with the bolt.

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

  3. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 1 transmission control cable bracket to the automatic transaxle assembly with the 2 bolts.

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

  4. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the 5 wire harness clamp brackets to the automatic transaxle assembly with the 5 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  5. INSTALL FRONT ENGINE MOUNTING BRACKET 
    1. Install the front engine mounting bracket to the automatic transaxle assembly with the 3 bolts.

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

  6. SUPPORT ENGINE ASSEMBLY 
    1. Set an engine lifter.
      GTY481485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that there is a clearance between the engine oil pan assembly and engine lifter.

  7. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.
      GTY568063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Clutch spline grease

      Toyota Genuine Clutch Spline Grease or equivalent

      Maximum spread

      Approximately 1 g (0.0353 oz)

      TEXT IN ILLUSTRATION

      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
    2. While keeping the engine and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the 10 bolts shown in the illustration.
      GTY562469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

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

      Bolt (B) 

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

      Bolt (C) 

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

      NOTE:
      • Confirm that the 2 knock pins are install to the automatic transaxle assembly contact surface of the engine cylinder block before installing the automatic transaxle assembly.
      • Make sure that the contact surfaces of the engine assembly and automatic transaxle assembly are flat against each other before tightening the bolts.
      • Do not use excessive force when installing the automatic transaxle assembly.
      • Check that the torque converter assembly rotates.
      • Make sure that the wire harness or other similar items are not pinched between the contact surfaces.
      • In order to protect the automatic transaxle oil pan sub-assembly, place attachments on the transmission jack.
      • Make sure that the attachments and automatic transaxle oil pan sub-assembly are centered on the transmission jack.
      • To prevent the automatic transaxle oil pan sub-assembly from being deformed, do not place any attachments under the automatic transaxle oil pan sub-assembly.
      • Secure the automatic transaxle assembly to the transmission jack using a belt, etc. to prevent it from falling.

      Bolt Length

      Bolt (A) 

      55 mm (2.17 in.)

      Bolt (B) 

      50 mm (1.97 in.)

      Bolt (C) 

      33 mm (1.30 in.)

    3. Clean and degrease the bolt and installation hole in the automatic transaxle assembly.
    4. Apply adhesive to 2 or 3 threads on the end of the bolt.
      GTY603782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Install the bolt.
      GTY555433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (D) 

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

      Bolt Length

      Bolt (D) 

      41 mm (1.61 in.)

  8. INSTALL BELT 
    1. Install SST to the vehicle body as shown in the illustration.
      GTY594444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09727-00110 
    2. Using the ratchet buckle, tighten the belt until there is no slack.
      GTY541656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Ratchet Buckle - -
  9. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator LH to the automatic transaxle assembly with the nut.

      Torque: 95 N*m (968 kgf*cm, 70 ft.*lbf) 

  10. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Install the front engine mounting insulator assembly to the front engine mounting bracket with the bolt.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

  11. REMOVE ENGINE SUPPORT BAR 
    1. Remove the 2 bolts and SST (support bar) from the vehicle body.
    2. Remove the nut, stud bolt and SST (support bar) from the engine mounting bracket RH.
  12. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH to the engine mounting bracket RH with the nut.

      Torque: 95 N*m (968 kgf*cm, 70 ft.*lbf) 

  13. INSTALL FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 14

  14. REMOVE BELT 
    1. Remove SST from the vehicle body.
      GTY572131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the windshield washer jar assembly to the vehicle body and tighten the bolt.

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

    3. Install the bolt and nut.

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

  15. REMOVE ENGINE SUPPORT BRIDGE 
    1. Remove SST from the vehicle body.
      NOTE:

      Prevent SST from contacting the vehicle body or windshield.

    2. Install the 2 hood support assemblies (Refer to INSTALLATION [10/2014 - ] ).
    3. Connect the pressure sensor assembly connector.
  16. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts and No. 1 and No. 2 engine hangers from the engine assembly.
  17. CONNECT NO. 1 RADIATOR HOSE 

    Refer to PROCEDURE - Step 5

  18. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 

    Refer to PROCEDURE - Step 35 and PROCEDURE - Step 35

  19. CONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Engage the clamp and connect the suction hose sub-assembly to the vehicle body.
    2. Remove the vinyl tape from the suction hose sub-assembly.
    3. Sufficiently apply compressor oil to a new O-ring and fitting surface of the suction hose sub-assembly.

      Compressor Oil

      ND-OIL 8 or equivalent

    4. Install the O-ring to the suction hose sub-assembly.
    5. Connect the suction hose sub-assembly.
    6. Rotate the hook connector as shown in the illustration.
      GTY472312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Insert the pipe joint to the fitting hole securely and tighten the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    (Refer to INSTALLATION [10/2014 - ] )

  21. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 21

  22. INSTALL ENGINE MOUNTING INSULATOR LH 

    Refer to PROCEDURE - Step 22

  23. INSTALL ENGINE MOUNTING INSULATOR RH 

    Refer to PROCEDURE - Step 23

  24. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

  25. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 
    1. Apply adhesive to 2 or 3 threads on the end of each of the 6 drive plate and torque converter assembly setting bolts.
      GTY603782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

      TEXT IN ILLUSTRATION

      *a Adhesive
    2. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

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

      NOTE:

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

  26. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 17

  27. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Front Side) 

    Refer to PROCEDURE - Step 18

  28. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    (Refer to INSTALLATION [10/2014 - ] )

  29. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    (Refer to INSTALLATION [10/2014 - ] )

  30. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    See step  2

  31. CONNECT WIRE HARNESS 
    1. Engage the 2 clamps and connect the wire harness to the front engine mounting insulator assembly.
    2. Connect the vacuum switching valve connector.
    3. Engage the 7 clamps and connect the wire harness to the automatic transaxle assembly.
    4. Connect the park/neutral position switch assembly connector.
    5. Connect the wire harnesses with the bolt.

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

  32. INSTALL TCM 

    See step  1

  33. INSTALL AIR CLEANER BRACKET 

    Refer to PROCEDURE - Step 39

  34. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  35. INSTALL TRANSMISSION OIL COOLER 
    1. Install the transmission oil cooler with the transmission oil cooler stay to the automatic transaxle assembly with the 2 bolts.

      Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 

    2. Connect the No. 1 oil cooler outlet hose and No. 1 oil cooler inlet hose to the transmission oil cooler and automatic transaxle assembly, and slide the 4 clips to secure them.
    3. Connect the No. 4 water by-pass hose to the water inlet pipe and transmission oil cooler and slide the 2 clips to secure them.
      GTY380432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the hose clamp so that the neck of the hose clamp is aligned with the paint.
      • Ensure that the paint is completely covered by the hose clamp.
      TEXT IN ILLUSTRATION

      *a Paint
    4. Engage the clamp to install the hose clamp to the No. 4 water by-pass hose.
    5. Connect the No. 1 breather plug (ATM) to the hose clamp.
  36. CONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 44

  37. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 53

  38. INSTALL INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 54

  39. INSTALL BATTERY 

    Refer to PROCEDURE - Step 55

  40. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 56

  41. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 57

  42. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  43. INSTALL INLET NO. 2 AIR CLEANER 

    Refer to PROCEDURE - Step 59

  44. INSPECT VACUUM HOSES 

    Refer to PROCEDURE - Step 60

  45. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  46. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to INSTALLATION [10/2014 - ] )

  47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 61

  48. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 8

  49. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  50. ADD AUTOMATIC TRANSAXLE FLUID 

    (Refer to ADJUSTMENT [10/2014 - ] )

  51. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  52. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  53. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  54. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR 

    Refer to PROCEDURE - Step 2

  55. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  56. INSPECT FOR OIL LEAK 
  57. INSPECT FOR EXHAUST GAS LEAK 
  58. CHECK FOR SPEED SENSOR SIGNAL 

    (Refer to TEST MODE PROCEDURE [10/2014 - 10/2015] or TEST MODE PROCEDURE [10/2015 - ] )

  59. INSPECT SHIFT LEVER POSITION 

    See step  1

  60. ADJUST SHIFT LEVER POSITION 

    See step  2

  61. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [10/2014 - 10/2015] or ADJUSTMENT [10/2015 - ] )

  62. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 82

  63. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3 and PROCEDURE - Step 3

  64. INSTALL FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 84

  65. INSTALL ENGINE UNDER COVER LH 

    Refer to PROCEDURE - Step 85

  66. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 

    Refer to PROCEDURE - Step 86

  67. INSTALL FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 87

  68. INSTALL ENGINE UNDER COVER RH 

    Refer to PROCEDURE - Step 88

  69. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 

    Refer to PROCEDURE - Step 89

  70. CHECK AUTOMATIC TRANSAXLE SYSTEM 
    NOTE:

    If automatic transaxle parts have been replaced, refer to Parts Replacement Compensation Table to determine if any additional operations are necessary (Refer to PRECAUTION [10/2014 - 10/2015] or PRECAUTION [10/2015 - ] ).

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