Installation

1. Install the torque converter clutch assembly.





A. Engage the splines of the input shaft and turbine runner.





B. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.

HINT

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





C. Turn the torque converter clutch assembly to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly.





D. Using a vernier caliper and a straightedge measure dimension "A" between the transaxle contact surfaces of the engine and the converter contact surfaces of the drive plate.

NOTICE

Make sure to deduct the thickness of the straightedge.





E. Using a vernier caliper and a straightedge measure dimension "B" shown in the illustration and check that "B" is greater than "A" which was measured in the previous step.

Standard: A + 1 mm (0.0394 in.) or more

NOTICE

^ Make sure to deduct the thickness of the straightedge.

^ If the transaxle is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.





2. Install the transmission case plug assembly.

A. Apply ATF to a new 0-ring and install it to the transmission case plug assembly.

B. Install the transmission case plug assembly to the automatic transaxle assembly.





3. Install the No. 1 transmission control cable bracket with the 2 bolts.

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





4. Install the front engine mounting bracket to the automatic transaxle with the 3 bolts.

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





5. Install the 4 wire harness clamp brackets to the automatic transaxle with the 4 bolts.

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





6. Install the flexible hose bracket sub-assembly.

A. Install the flexible hose bracket sub-assembly to the transaxle with the bolt.

Torque: 20 N*m (204 kgf*cm, 15 ft*lbf)

B. Install the breather plug hose to the flexible hose bracket sub-assembly with the clip.





7. Install the Transmission Control Module (TCM) to the transaxle and tighten the 2 bolts in the order shown in the illustration.

Torque: 11 N*m (112 kgf*cm, 8 ft*lbf)

8. Install the automatic transaxle assembly.





A. Apply clutch spline grease to the contact surface between the crankshaft and torque converter centerpiece.

Clutch spline grease:
Toyota Genuine Clutch Spline Grease, or equivalent

Maximum Amount:
1 g (0.0353 oz.)





B. Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before transaxle installation.

9. Install the lower (5) transaxle bolts.





Keeping the engine and automatic transaxle assembly in a horizontal position align the knock pins with each hole on the automatic transaxle assembly and tighten the 5 bolts shown in the illustration.

Bolt A:

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

Bolt B:

Torque: 44 N*m (449 kgf*cm, 32 ft*lbf)

NOTICE

^ Do NOT forcibly pry on the automatic transaxle assembly.

^ Check that the torque converter rotates.

^ Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before transaxle installation.

10. Lower the transmission jack away from the engine and transmission.

11. Install the 6 drive plate and torque converter clutch setting bolts.





A. Using the SSTs hold the crankshaft pulley.

SST: 09213-54015, 09330-00021, 91551-80650





B. Apply a few drops of adhesive to the first 2 or 3 threads of the 6 drive plate and torque converter clutch setting bolts.

Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324, or equivalent





C. Install the 6 drive plate and torque converter clutch setting bolts.

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

NOTICE

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





12. Install the flywheel housing under cover.

13. Install the sub frame using the SST.

SST: 00002-90080





A. Install the front frame assembly with the 9 nuts.

Front Side:

Torque: 52 N*m (531 kgf*cm, 38 ft*lbf)

RH & LH Sides:

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





B. Install the 5 hole plugs.





C. Install the power steering link assembly with the 2 bolts and 2 nuts.

Torque: 70 N*m (714 kgf*cm, 52 ft*lbf)





D. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.

Nut A:

Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)

Bolt B:

Torque: 32 N*m (329 kgf*cm, 24 ft*lbf)

E. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

Nut C:

Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)

Bolt D:

Torque: 32 N*m (329 kgf*cm, 24 ft*lbf)

HINT

SST 00002-90080 will ensure all engine and transmission mount studs have lined up with their corresponding holes.

14. Remove the secondary safety support straps.





15. Install the front stabilizer link assembly with the nut.

Torque: 74 N*m (755 kgf*cm, 55 ft*lbf)

HINT

If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

16. Install the front exhaust pipe assembly back onto the vehicle.





A. Install 2 new gaskets to the front exhaust pipe assembly and center exhaust pipe assembly.

B. Install the front exhaust pipe with the 2 nuts to the exhaust manifold converter sub-assembly.

Torque: 55 N*m (561 kgf*cm, 40 ft*lbf)

C. Install the front exhaust pipe with the 2 nuts and 2 bolts to the center exhaust pipe assembly.

Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)

D. Install the bracket with the 2 nuts.

Torque: 33 N*m (337 kgf*cm, 24 ft*lbf)





E. Install the support bracket with the 2 bolts.

Torque: 33 N*m (337 kgf*cm, 24 ft*lbf)





F. Connect the connector.





17. Install the front drive shaft assembly LH.





A. Coat the spline of the inboard joint shaft assembly with ATF.

B. Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.

NOTICE

^ Set the shaft snap ring with the opening side facing down.

^ Be careful NOT to damage the drive shaft dust cover, boot, or oil seal.

^ Move the drive shaft assembly while keeping it level.





18. Install the front drive shaft assembly RH.

A. Coat the spline of the inboard joint shaft assembly with ATF.

B. Install the front drive shaft assembly RH.

C. Using a screwdriver install a new bearing bracket hole snap ring.

D. Install a new bolt.

Torque: 32 N*m (330 kgf*cm, 24 ft*lbf)

NOTICE

^ Do NOT damage the boot and oil seal.

^ Move the drive shaft assembly while keeping it level.

19. Install the front axle assembly.





Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

20. Install the front suspension lower No.1 arm.





Install the lower ball joint to the front suspension lower No.1 arm with the bolt and 2 nuts.

Torque: 75 N*m (765 kgf*cm, 55 ft*lbf)





21. Install the front axle hub nut.

A. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.

B. Using a socket wrench (30 mm) and applying the brakes install a new front axle hub nut.

Torque: 294 N*m (3,000 kgf*cm, 217 ft*lbf)

C. Using a chisel and hammer stake the front axle hub nut.

22. Install the front wheels.

23. Install the front wheel opening extension pad LH.

24. Install the engine under cover LH.

25. Install the front wheel opening extension pad RH.

26. Install the front fender apron seal LH.

27. Install the front fender apron seal RH.

28. Remove the Engine Support Bar.

29. Install the upper (4) transaxle bolts

Bolt A:

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

Bolt B:

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

NOTE

^ Do NOT forcibly pry on the automatic transaxle assembly.

^ Check that the torque converter rotates.





30. Install the transmission oil cooler.

A. Install the transmission oil cooler to the front engine mounting bracket with the 3 bolts.

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

B. Connect the No.1 oil cooler outlet hose and No.1 oil cooler inlet hose.

31. Connect the transmission control cable assembly.





Install a new clip and nut and connect the cable to the transaxle.

Torque: 13 N*m (130 kgf*cm, 9 ft*lbf)

32. Connect the engine wire.





A. Install the positive (+) cable with the nut and 2 clamps.

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





B. Install the air cleaner bracket with the 2 bolts.

Torque: 7.8 N*m (80 kgf*cm, 69 in*lbf)





C. Connect the ground cable with the bolt.

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





D. Connect the ground cable with the bolt.

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

33. Install the starter assembly.





A. Install the starter assembly with the 2 bolts.

Torque: 37 N*m (377 kgf*cm, 27 ft*lbf)





B. Connect the wire harness to terminal 30 and install the nut. Then attach the terminal cap.

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

C. Connect the terminal 50 connector to the starter assembly.





34. Install the air cleaner case sub-assembly.

A. Install the air cleaner case with the 3 bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)

B. Connect the wire harness clamp.

35. Install the air cleaner cap sub-assembly.





A. Connect the air cleaner cap sub-assembly with the hose clamp.





B. Connect the hose with the hose clamp.





C. Engage the hose with the hose clamp.





D. Connect the vacuum switching valve connector and 2 hoses.





E. Connect the mass air flow meter connector and wire harness clamp to the air cleaner cap sub-assembly.





F. For PZEV vehicles: Connect the hose and engage the hose to the clips on the air cleaner hose.





G. Install the air cleaner cap sub-assembly with the 2 bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)





36. Install the inlet air cleaner assembly with the 2 bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)





37. Fit the 3 retainers and install the No. 1 engine cover sub-assembly.





38. Install the battery.

A. Install the battery and battery tray.

B. Install the battery clamp with the bolt and nut.

Bolt:

Torque: 9.0 N*m (92 kgf*cm, 80 in*lbf)

Nut:

Torque: 3.5 N*m (36 kgf*cm, 31 in*lbf)

C. Connect the battery terminals.

Torque: 6.9 N*m (70 kgf*cm, 61 in*lbf)

39. Fill transmission to correct level with transaxle fluid using SST 00002-11100-02.

SST: 00002-11100-02

40. Check for exhaust leaks.

41. Check for fluid leaks.

42. Check shift lever position.

43. Install the engine under covers.

44. Re-initialize auto-power windows and moon roof (if equipped).

45. Test drive vehicle insuring proper operation.

46. Adjust wheel alignment as needed.