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Installation





U340E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION

1. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY

(a) Apply Toyota Genuine ATF WS or equivalent to a new O-ring, and install it onto the oil filler tube.

(b) Install the oil filler tube onto the automatic transaxle with the bolt.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)





2. INSTALL TRANSMISSION OIL LEVEL GAUGE SUB-ASSEMBLY

(a) Install the oil level gauge into the oil filler tube.

3. INSTALL NO. 2 OIL COOLER TUBE CLAMP





(a) Provisionally install outlet No. 1 oil cooler tube into the oil cooler tube union.

(b) Provisionally install inlet No. 1 oil cooler tube into the oil cooler tube union.

(c) Provisionally install No. 2 oil cooler tube clamp onto the oil level gauge with the bolt.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

4. INSTALL OUTLET NO. 1 OIL COOLER TUBE





(a) Using a union nut wrench, install the outlet No. 1 oil cooler tube while holding the oil cooler tube union with a wrench.

For use without union nut wrench - Torque : 34 Nm (347 kgf-cm, 32 ft-lbf)

For use with union nut wrench - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

HINT
* This torque value can be obtained by using a torque wrench with a fulcrum length of 345 mm (13.58 in.) and a union nut wrench with a fulcrum length of 30 mm (1.18 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.
5. INSTALL INLET NO. 1 OIL COOLER TUBE





(a) Using a union nut wrench, install the inlet No. 1 oil cooler tube while holding the oil cooler tube union with a wrench.

For use without union nut wrench - Torque : 34 Nm (347 kgf-cm, 32 ft-lbf)

For use with union nut wrench - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

HINT
* This torque value can be obtained by using a torque wrench with a fulcrum length of 345 mm (13.58 in.) and a union nut wrench with a fulcrum length of 30 mm (1.18 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.
6. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET





(a) Install No. 1 transmission control cable bracket onto the automatic transaxle with the 2 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

7. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY Testing and Inspection

8. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

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





(b) Put a mark on the torque converter so that its groove is clearly indicated.





(c) Align the mark on the case with the one on the torque converter and fit the spline of the input shaft to the spline of the turbine runner.





(d) Rotating the torque converter, fit the spline of the stator shaft with that of the stator.





HINT
Rotate it approximately 180 degrees.

(e) Rotating the torque converter, align the mark on the case with the one on the torque converter again and fit the key of the oil pump drive gear into the keyway of the torque converter.





NOTICE:
Do not push the converter excessively when rotating it.

(f) Using a vernier caliper and a straightedge, measure the dimension A between the automatic transaxle fitting surface (*1) of the engine and the torque converter fitting surface (*2) of the drive plate.





NOTICE:
Subtract the thickness of the straightedge from the measured value to gain dimension A.

HINT
The converter fitting surface and the ring gear side surface are at the same level.

(g) Using a vernier caliper and a straightedge, measure dimension B shown in the illustration and check that dimension B is greater than dimension A, which was measured in step (f).





Standard:

A + 1 mm (0.04 in.) or more

NOTICE:
Subtract the thickness of the straightedge from the measured value to gain dimension B.

9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

(a) Apply clutch spline grease to the round of the crankshaft contact surface (*1) with the torque converter centerpiece.





Clutch spline grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum spread:

Approximately 1 g (0.353 oz)

(b) Install the automatic transaxle onto the engine with the 7 bolts.





Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

NOTICE:
* Confirm that 2 knock pins are on the transaxle fitting surface of the engine block before transaxle installation.
* After installing the transmission, confirm that the torque converter rotates smoothly.
(c) Remove any adhesive remaining in the 6 bolt holes of the torque converter clutch and 6 bolts.





(d) Apply adhesive to 2 or 3 threads on the end of the 6 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(e) Install the 6 torque converter set bolts while holding the crankshaft pulley bolt with a wrench.





Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

(f) Install the flywheel housing under cover.





10. INSTALL ENGINE MOUNTING BRACKET LH

(a) Remove any adhesive remaining in the 4 bolt holes on the engine mounting bracket LH and 4 bolts.





(b) Apply adhesive to 2 or 3 threads on the end of the 4 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the engine mounting bracket LH onto the automatic transaxle with the 4 bolts.





Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

11. INSTALL ENGINE MOUNTING INSULATOR LH





(a) Install the engine mounting insulator LH and the engine mounting bracket LH with the bolt and nut.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

12. INSTALL ENGINE MOVING CONTROL ROD BRACKET





(a) Install the engine moving control bracket onto the automatic transaxle with the 3 bolts.

Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)

13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation

14. INSTALL ENGINE MOVING CONTROL ROD





(a) Install the engine moving control rod and the engine moving control bracket with the bolt and nut.

Torque : 120 Nm (1,224 kgf-cm, 89 ft-lbf)

15. INSTALL OUTLET OIL COOLER HOSE





(a) Install the outlet oil cooler hose onto the outlet oil cooler tube.

16. INSTALL INLET OIL COOLER HOSE

(a) Install the inlet oil cooler hose onto the inlet oil cooler tube.

17. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

18. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

19. REMOVE AUTOMATIC TRANSMISSION CASE PROTECTOR (w/o ABS) Installation

20. INSTALL FRONT AXLE ASSEMBLY LH Installation

21. INSTALL FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure for the LH side and RH side.

22. INSTALL FRONT LOWER SUSPENSION ARM LH Installation

23. INSTALL FRONT LOWER SUSPENSION ARM RH

HINT
Use the same procedure for the LH side and RH side.

24. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation

25. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT
Use the same procedure for the LH side and RH side.

26. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

27. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure for the LH side and RH side.

28. INSTALL FRONT SPEED SENSOR LH (w/ ABS) Installation

29. INSTALL FRONT SPEED SENSOR RH (w/ ABS)

HINT
Use the same procedure for the LH side and RH side.

30. INSTALL FRONT AXLE HUB NUT LH Installation

31. INSTALL FRONT AXLE HUB NUT RH

HINT
Use the same procedure for the LH side and RH side.

32. INSTALL STARTER ASSEMBLY Installation

33. CONNECT WIRE HARNESS





(a) Install the 3 wire harness clamp brackets onto the automatic transaxle with the 3 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

34. CONNECT CONNECTOR

(a) Connect the vehicle speed sensor connector.

(b) Connect the transmission revolution sensor connector.

(c) Connect the transmission wire connector and install the clamp onto the engine mount insulator.

(d) Connect the park neutral position switch connector and install the clamp onto the engine mount insulator.

35. INSTALL NO. 3 ENGINE WIRE





(a) Install No. 3 engine wire onto the automatic transaxle with the bolt.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)

(b) Install the 2 clamps onto the engine mount insulator.

36. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY Installation

37. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

38. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY Installation

39. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

40. INSTALL AIR CLEANER BRACKET Installation

41. INSTALL AIR CLEANER ASSEMBLY Installation

42. INSTALL NO. 2 CYLINDER HEAD COVER

(a) Tighten the 2 A nuts, then the 2 B nuts.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

43. INSTALL BATTERY CARRIER Installation

44. INSTALL BATTERY TRAY

45. INSTALL BATTERY Installation

46. INSTALL OUTER COWL TOP PANEL

Hatchback: Installation

Sedan: Installation

47. INSTALL COWL TO REGISTER DUCT SUB-ASSEMBLY (for Hatchback) Installation

48. INSTALL FRONT AIR SHUTTER SEAL (for Sedan) Installation

49. INSTALL FRONT WIPER MOTOR AND LINK

Hatchback: Installation

Sedan: Installation

50. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback) Installation

51. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Hatchback: Installation

Sedan: Installation

52. INSTALL HOOD TO COWL TOP SEAL (for Hatchback) Installation

53. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) Installation

54. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) Installation

55. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

Hatchback: Installation

Sedan: Installation

56. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

Hatchback: Installation

Sedan: Installation

57. INSTALL FRONT WIPER ARM HEAD CAP

Hatchback: Installation

Sedan: Installation

58. TEMPORARILY TIGHTEN HOOD SUB-ASSEMBLY

Hatchback: Installation

Sedan: Installation

59. INSPECT HOOD SUB-ASSEMBLY

Hatchback: Hood (for Hatchback)

Sedan: Hood (for Sedan)

60. ADJUST HOOD SUB-ASSEMBLY

Hatchback: Hood (for Hatchback)

Sedan: Hood (for Sedan)

61. ADD AUTOMATIC TRANSAXLE FLUID

Automatic Transaxle Fluid:





62. INSPECT AUTOMATIC TRANSAXLE FLUID Procedures

63. CHECK AUTOMATIC TRANSAXLE FLUID LEAKAGE

64. ADJUST SHIFT LEVER POSITION Adjustments

65. INSPECT SHIFT LEVER POSITION U340E Automatic Transaxle

66. INSTALL ENGINE UNDER COVER RH

67. INSTALL ENGINE UNDER COVER LH

68. INSTALL FRONT WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

69. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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