Installation
U151E AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION
INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Install the torque converter clutch to the automatic transaxle.
(b) Using vernier calipers and a straight edge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (#).
(c) Aligning the matchmarks on the transmission case and torque converter clutch assembly, engage the splines of the input shaft and turbine runner.
NOTE: Do not push on the torque converter when aligning the matchmarks.
(d) Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.
HINT: Turn the torque converter clutch assembly approximately 180°.
(e) Turn the torque converter clutch assembly and align the matchmarks on the torque converter clutch assembly and transmission case to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly.
(f) Using vernier calipers and a straight edge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (#)).
Standard:
A + 1 mm (0.04 in.) or more
NOTE: Make sure to deduct the thickness of the straight edge.
2. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER
(a) Install the automatic transaxle with transfer to the engine with the 10 bolts.
Bolt A - Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
Bolt B - Torque: 46 Nm (470 kgf-cm, 34 ft-lbf)
Bolt C - Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
(b) Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft-lbf)
NOTE: First install the green colored bolt, and then the remaining 5 bolts.
(d) Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
3. INSTALL ENGINE MOUNTING BRACKET FRONT
(a) Install the engine mounting bracket front to the automatic transaxle with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
4. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the transmission oil filler tube sub-assembly.
(b) Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
5. INSTALL NO. 1 OIL COOLER INLET TUBE
(a) Temporarily install the No. 1 oil cooler outlet tube.
(b) Temporarily install the No. 1 oil cooler inlet tube.
(c) Install the oil cooler tube clamp with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
HINT: Install them so that the oil cooler tube cushion is positioned as shown in the illustration.
(d) Install the No. 1 oil cooler inlet tube.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
6. INSTALL NO. 1 OIL COOLER OUTLET TUBE
(a) Install the No. 1 oil cooler outlet tube.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
7. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET
(a) Install the No.1 control cable bracket with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 10 ft-lbf)
8. CONNECT BREATHER PLUG HOSE
(a) Connect the breather hose to the oil filler tube.
9. CONNECT CONNECTORS
(a) Connect the transmission wire connector.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 transmission revolution sensor connectors.
10. INSTALL STARTER ASSEMBLY
11. CONNECT WIRE HARNESS
(a) Connect the wire harness with the bolt.
Torque: 19 Nm (193 kgf-cm, 14 ft-lbf)
12. INSTALL WIRE HARNESS CLAMP
(a) Install the 4 clamps and 4 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(b) Connect the wire harnesses to the clamps.
13. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET
(a) Install the No. 2 transmission control cable bracket with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
14. INSTALL MANIFOLD STAY Installation
15. INSTALL ENGINE WIRE
16. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
17. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
18. INSTALL FRONT FRAME ASSEMBLY Installation
19. INSTALL VANE PUMP ASSEMBLY Installation
20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation
21. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
22. INSTALL GENERATOR ASSEMBLY
23. INSTALL HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT LH (w/ Air Suspension) Installation
24. INSTALL HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT RH (w/ Air Suspension) Installation
25. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
26. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation
27. INSTALL FRONT AXLE ASSEMBLY LH Installation
28. INSTALL FRONT AXLE ASSEMBLY RH Installation
29. CONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH Installation
30. CONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER RH Installation
31. INSTALL TIE ROD ASSEMBLY LH Installation
32. INSTALL TIE ROD ASSEMBLY RH Installation
33. INSTALL FRONT SPEED SENSOR LH Installation
34. INSTALL FRONT SPEED SENSOR RH Installation
35. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
36. INSTALL FRONT STABILIZER LINK ASSEMBLY RH Installation
37. INSTALL FRONT AXLE HUB NUT LH Installation
38. INSTALL FRONT AXLE HUB NUT RH Installation
39. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation
40. INSTALL NO. 3 EXHAUST PIPE SUB-ASSEMBLY FRONT Installation
41. INSTALL OXYGEN SENSOR Installation
42. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE Installation
43. CONNECT RETURN TUBE SUB-ASSEMBLY Installation
44. CONNECT FUEL TUBE SUB-ASSEMBLY Installation
45. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation
46. CONNECT ENGINE WIRE Installation
47. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
48. INSTALL JUNCTION BLOCK COVER
49. CONNECT HEATER INLET WATER HOSE Installation
50. CONNECT HEATER OUTLET WATER HOSE Installation
51. CONNECT OIL COOLER INLET HOSE Installation
52. CONNECT OIL COOLER OUTLET HOSE Installation
53. INSTALL RADIATOR HOSE INLET Installation
54. INSTALL RADIATOR HOSE OUTLET Installation
55. CONNECT UNION TO CHECK VALVE HOSE Installation
56. CONNECT NO. 1 FUEL VAPOR FEED HOSE Installation
57. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Installation
58. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation
59. INSTALL AIR CLEANER BRACKET Installation
60. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Installation
61. INSTALL BATTERY Installation
62. INSTALL NO. 1 AIR CLEANER INLET Installation
63. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
65. INSTALL NO. 2 AIR CLEANER INLET Installation
66. CONNECT VACUUM HOSES Installation
67. INSTALL V-RIBBED BELT Installation
68. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation
69. INSTALL WINDSHIELD WIPER LINK ASSEMBLY Installation
70. INSTALL FRONT WHEELS
HINT:
71. ADD ENGINE OIL
72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation
73. ADD ENGINE COOLANT Testing and Inspection
74. ADD AUTOMATIC TRANSAXLE FLUID
75. ADD POWER STEERING FLUID
76. BLEED POWER STEERING FLUID
77. CHECK FOR FUEL LEAKS Testing and Inspection
78. CHECK FOR ENGINE OIL LEAKS
79. CHECK FOR ENGINE COOLANT LEAKS Testing and Inspection
80. CHECK FOR EXHAUST GAS LEAKS
81. INSPECT SHIFT LEVER POSITION Adjustments
82. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Installation
83. INSPECT IGNITION TIMING Engine
84. INSPECT ENGINE IDLE SPEED Engine
85. INSPECT CO/HC Engine
86. INSPECT THROTTLE BODY On-Vehicle Inspection
87. INSTALL FRONT FENDER APRON SEAL RH
88. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
89. INSTALL NO. 2 ENGINE UNDER COVER (w/ No. 2 engine under cover)
90. INSTALL NO. 1 ENGINE UNDER COVER
91. INSTALL ENGINE UNDER COVER ASSEMBLY (w/ engine under cover assembly)
92. INSTALL V-BANK COVER SUB-ASSEMBLY Installation
93. INSTALL ENGINE ROOM COVER SIDE (for LHD) Installation
94. INSTALL COOL AIR INTAKE DUCT SEAL Installation
95. CHECK ABS SPEED SENSOR SIGNAL
96. RESET MEMORY
Programming and Relearning
97. PREFORM INITIALIZATION
HINT: Some systems need initialization after reconnecting the cable to the negative battery terminal Repair Instruction - Initialization.