Installation

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL REAR ENGINE MOUNTING BRACKET

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

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

(a) Install the bracket to the automatic transaxle with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
4. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

(a) Using a vernier caliper, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate.

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

(d) Match the 2 marks on the transaxle case and the torque converter clutch and fit the spline 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 with the spline part of the stator.
HINT: Rotate it about 180°.

(f) Rotating the torque converter clutch, match 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.
NOTE: When rotating the torque converter clutch, do not push it with excessive force.

(g) Using a vernier caliper and straightedge, measure dimension B shown in the illustration and check that B is greater than A.
Standard dimension:
B = A + 1.0 mm (0.039 in.) or more
5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

(a) Install the transaxle to the engine with the 7 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
Torque: 46 Nm (469 kgf-cm, 34 ft-lbf)
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)

(b) Install the 6 torque converter clutch mounting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft-lbf)
HINT: First install the black colored bolt, and then the remaining 5 bolts.

6. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the cover to the automatic transaxle.
7. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the 5 bolts and nut.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
Torque: 87 Nm (887 kgf-cm, 64 ft-lbf)
8. INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY

(a) Install the engine mounting member with the 4 bolts.
Torque: 45 Nm (459 kgf-cm, 33 ft-lbf)
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf)
9. INSTALL REAR ENGINE MOUNTING INSULATOR

(a) Install the insulator to the rear engine mounting bracket with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft-lbf)

(b) Tighten the 3 nuts and bolt.
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf)
10. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the insulator to the front engine mounting bracket with the bolt and nut.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
11. INSTALL STARTER ASSEMBLY

(a) Install the starter with the 2 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
(b) Connect the connector.
(c) Install the starter wire with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
12. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Install the drive shaft Installation.
13. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
(a) Install the drive shaft Installation.
14. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install the exhaust pipe Installation.
15. INSTALL NO. 1 OIL COOLER OUTLET TUBE

(a) Tighten the No. 1 oil cooler outlet tube.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
16. INSTALL NO. 1 OIL COOLER INLET TUBE
(a) Tighten the No. 1 oil cooler inlet tube.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)

(b) Install the 2 oil cooler tube clamps with the 2 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
17. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the cable bracket to the automatic transaxle with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
18. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY

(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 in-lbf)
(c) Install the ATF level gauge.
19. INSTALL TRANSMISSION CONTROL CABLE CLAMP

(a) Install the transmission control cable support to the automatic transaxle with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
20. INSTALL BREATHER PLUG HOSE

(a) Install the hose to the oil filler tube sub-assembly and automatic transaxle.
21. CONNECT CONNECTOR

(a) Connect the 2 clamps to the oil filler tube.
(b) Connect the transmission wire connector.
(c) Connect the park/neutral position switch connector.
(d) Connect the 2 speed sensor connectors.
22. INSTALL WIRE HARNESS

(a) Install the harness and wire harness bracket with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
23. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install the cable and clip to the bracket.

(b) Temporarily install the cable to the control shaft lever with the nut.
24. INSTALL AIR CLEANER ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
25. INSTALL BATTERY CARRIER

(a) Install the carrier to the body with the 4 bolts.
Torque: 13 Nm (132 kgf-cm, 10 ft-lbf)
26. INSTALL BATTERY
27. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
28. INSTALL HOOD SUB-ASSEMBLY
Torque: 13 Nm (132 kgf-cm, 10 ft-lbf)
29. INSPECT HOOD SUB-ASSEMBLY
(a) Inspect the food Adjustments.
30. ADJUST HOOD SUB-ASSEMBLY
(a) Adjust the food Adjustments.
31. ADD AUTOMATIC TRANSAXLE FLUID
Fluid type:
Toyota Genuine ATF WS
Standard capacity:
3.5 liters (3.7 US qts, 3.1 Imp.qts)
32. ADJUST SHIFT LEVER POSITION
(a) Adjust the lever position Adjustments.
33. INSPECT SHIFT LEVER POSITION
(a) Inspect the lever position Adjustments.
34. INSPECT AUTOMATIC TRANSAXLE FLUID
(a) Inspect the fluid Procedures.
35. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the wheel alignment Front Wheel Alignment.
36. CHECK ABS SPEED SENSOR SIGNAL
(a) Check the sensor signal C0200.
37. RESET MEMORY
(a) Reset memory (AT initialization) Programming and Relearning.
38. PERFORM INITIALIZATION
(a) Perform initialization Testing and Inspection.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

39. INSTALL ENGINE UNDER COVER LH
40. INSTALL ENGINE UNDER COVER RH
41. INSTALL FRONT WHEEL
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)