Installation

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it into the speedometer driven hole cover sub-assembly.

(b) Install the speedometer driven hole cover sub-assembly onto the automatic transaxle.
Torque: 7.0 Nm (71 kgf-cm, 61 in-lbf)
2. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it onto the transmission oil filler tube sub-assembly.

(b) Install the transmission oil filler tube sub-assembly onto the automatic transaxle with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
3. INSTALL TRANSMISSION OIL LEVEL GAUGE SUB-ASSEMBLY
(a) Install the transmission oil level gauge sub-assembly into the transmission oil filler tube sub-assembly.
4. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the No. 1 transmission control cable bracket onto the automatic transaxle with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
5. INSTALL ENGINE MOUNTING BRACKET LH

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

(a) Install the rear engine mounting bracket onto the automatic transaxle with the 3 bolts.
Torque: 45 Nm (459 kgf-cm, 33 ft-lbf)
7. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR
(a) Provisionally install the rear engine mounting insulator and the rear engine mounting bracket with the bolt.
HINT: Tighten the bolt to the specified torque after tighten rear engine mounting insulator.

8. INSTALL FRONT ENGINE MOUNTING BRACKET

(a) Install the front engine mounting bracket onto the automatic transaxle with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
9. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

(a) Provisionally install the front engine mounting insulator and the front engine mounting bracket with the bolt and nut.
HINT: Tighten the bolt and nut to the specified torque after tightening front engine mounting insulator.

10. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY
(See ( Testing and Inspection))
11. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

(a) Using vernier calipers, 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 at the top of the front oil pump drive gear and put a matchmark on the housing.

(d) Align the matchmark on the case with the one on the converter and fit the spline on the input shaft to the spline on the turbine runner.

(e) Rotating the converter, fit the stator shaft spline with the one on the stator.
HINT: Rotate it approximately 180 degrees.

(f) Rotating the converter, align the matchmark on the case with the one on the converter again and fit the oil pump drive gear key into the keyway on the converter.
NOTICE: Do not push the converter excessively when rotating it.

(g) Using vernier calipers and a straight edge, measure dimension B shown in the illustration and check that dimension B is greater than dimension A, which was measured in step [*1].
Standard:
A + 1 mm (0.04 in.) or more
NOTICE: Subtract the thickness of the straight edge from the measured value to gain dimension B.

12. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

(a) Install the automatic transaxle with the 5 upper side mounting bolts onto the engine.
Bolt A - Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
Bolt B - Torque: 46 Nm (469 kgf-cm, 34 ft-lbf)

(b) Install the 4 lower side mounting bolts.
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf)
13. TEMPORARILY TIGHTEN ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the 4 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)

(b) Provisionally install the engine mounting insulator LH and the engine mounting bracket LH with the bolt and nut.
HINT: Tighten the bolt and nut to the specified torque after tighten engine mounting insulator LH.

14. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Support the front suspension crossmember with a transmission jack.
(b) While inserting SST into the reference holes on the front suspension crossmember RH and LH alternately, tighten 2 bolts A, 2 bolts B, and 2 nuts on the RH and LH sides to the respective specified torque in several steps.

SST: 09670-00020
Bolt A - Torque: 145 Nm (1479 kgf-cm, 107 ft-lbf)
Bolt B - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
15. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

(a) Install the front suspension member rear brace LH with the 3 bolts.
Bolt A - Torque: 145 Nm (1479 kgf-cm, 107 ft-lbf)
Bolt B - Torque: 93 Nm (948 kgf-cm, 69 ft-lbf)
16. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH
HINT: Use the same procedure as for the LH side.

17. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY

(a) Install the front crossmember with the 6 bolts.
Bolt A - Torque: 96 Nm (979 kgf-cm, 71 ft-lbf)
Bolt B - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
18. TIGHTEN REAR ENGINE MOUNTING INSULATOR

(a) Tighten the bolt.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
19. TIGHTEN FRONT ENGINE MOUNTING INSULATOR

(a) Tighten the bolt and nut.
Torque: 145 Nm (1479 kgf-cm, 107 ft-lbf)
20. TIGHTEN ENGINE MOUNTING INSULATOR LH

(a) Tighten the bolt and nut.
Torque: 56 Nm (571 kgf-cm, 41 ft-lbf)
21. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

(a) Install the front suspension member reinforcement LH with the 4 bolts.
Torque: 96 Nm (979 kgf-cm, 71 ft-lbf)
NOTICE: Temporarily tighten bolts A and B, and then fully tighten the 4 bolts in the order of C, B, D, and A.

22. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
HINT: Use the same procedure as for the LH side.

23. INSTALL TORQUE CONVERTER CLUTCH AND DRIVE PLATE SET BOLT
(a) Apply adhesive to the 6 bolts.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

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

(c) Install the flywheel housing under cover.
24. INSTALL NO.2 OIL COOLER TUBE SUB-ASSEMBLY

(a) Install the No. 2 oil cooler tube sub-assembly onto the automatic transaxle assembly with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) Connect the 2 oil cooler hoses onto the 2 oil cooler tube unions.
25. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Using vernier calipers, measure the free length of the compression spring.
Minimum length:
41.5 mm (1.634 in.)
If the length is not as specified, replace the compression spring.

(b) Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold and front exhaust pipe assembly.

NOTICE:
- Install the exhaust pipe gasket in the correct direction.
- Do not damage the outer surface of the exhaust pipe gasket.
- Do not reuse the exhaust pipe gasket.
- Do not push in the gasket with the exhaust pipe when connecting it.

(c) Install the front exhaust pipe assembly onto the exhaust manifold with the 2 bolts and 2 compression springs.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)

(d) Install a new gasket, 2 bolts and install the front exhaust pipe assembly onto the center exhaust pipe assembly.
Install the front exhaust pipe assembly onto the center exhaust pipe assembly with a new gasket and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)

(e) Connect the heated oxygen sensor connector.
26. INSTALL FRONT DRIVE SHAFT ASSEMBLY
HINT: See the steps from "INSTALL FRONT DRIVE SHAFT ASSEMBLY LH" through "FRONT AXLE HUB NUT RH" ( Installation).

27. INSTALL STARTER ASSEMBLY Installation
28. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install the transmission control cable assembly into the control shaft lever with the nut.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) Fix the transmission control cable assembly onto the transmission control cable bracket with a new clip.

(c) Install the transmission control cable support onto the automatic transaxle assembly with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
29. CONNECT NO. 3 ENGINE WIRE

(a) Install the No. 3 engine wire onto the automatic transaxle assembly with the bolt.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
(b) Connect the No. 3 engine wire clamp.
30. CONNECT WIRE HARNESS

(a) Install the engine wire clamp onto the automatic transaxle assembly with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)

(b) Connect the engine wire clamp.
31. CONNECT CONNECTORS
(a) Connect the park/neutral position switch connector.
(b) Connect the transmission wire connector.
(c) Connect the speed sensor NT connector.
(d) Connect the speed sensor NC connector.
32. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case sub-assembly with the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
33. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
(a) Install the air cleaner filter element onto the air cleaner case.
34. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
35. INSTALL NO. 2 BATTERY CARRIER

(a) Install the battery carrier assembly with the 4 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
36. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
37. INSTALL OUTER COWL TOP PANEL

(a) Install the cowl top panel outer with the 10 bolts.
Torque: 8.8 Nm (90 kgf-cm, 78 in-lbf)
38. INSTALL FRONT WIPER MOTOR AND LINK Installation
39. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
40. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
41. INSTALL HOOD TO COWL TOP SEAL Installation
42. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
43. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
44. INSTALL REAR WIPER ARM HEAD CAP Installation
45. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation
46. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
47. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
48. INSTALL FRONT WHEELS
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)
49. TEMPORARILY TIGHTEN HOOD SUB-ASSEMBLY Installation
50. INSPECT HOOD SUB-ASSEMBLY Adjustments
51. ADJUST HOOD SUB-ASSEMBLY Adjustments
52. INSTALL BATTERY Installation
53. ADD AUTOMATIC TRANSAXLE FLUID
Fluid type:
Toyota Genuine ATF WS
54. INSPECT AUTOMATIC TRANSAXLE FLUID Procedures
55. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK
56. INSPECT FOR EXHAUST GAS LEAK
57. INSPECT SHIFT LEVER POSITION On-Vehicle Inspection
58. ADJUST SHIFT LEVER POSITION Installation
59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
Front Wheel Alignment

60. INSTALL NO. 2 ENGINE UNDER COVER
61. INSTALL REAR ENGINE UNDER COVER LH
62. INSTALL REAR ENGINE UNDER COVER RH
63. INSTALL CENTER TRANSMISSION UNDER COVER ASSEMBLY
64. INSTALL NO. 1 ENGINE UNDER COVER