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Installation








U151E AUTOMATIC TRANSAXLE: 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 transaxle 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 transaxle 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 TRANSAXLE ASSEMBLY






(a) Install the automatic transaxle 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 different 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 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)
4. 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) Using union nut wrench (17 mm), install the No. 1 oil cooler inlet tube while holding the union with a wrench.
Without union nut wrench - Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
With union nut wrench - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
NOTICE:
- Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
- This torque value is effective when union nut wrench is parallel to a torque wrench.

5. INSTALL NO. 1 OIL COOLER OUTLET TUBE






(a) Using union nut wrench, install the No. 1 oil cooler outlet tube while holding the union with a wrench.
Without union nut wrench - Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
With union nut wrench - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
NOTICE:
- Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
- This torque value is effective when union nut wrench is parallel to a torque wrench.

6. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET






(a) Install the No. 1 transmission control cable bracket with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
7. CONNECT BREATHER PLUG HOSE






(a) Connect the breather plug hose to the oil filler tube.
8. CONNECT CONNECTORS






(a) Connect the transmission wire connector.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 speed sensor connectors.
9. CONNECT WIRE HARNESS






(a) Connect the wire harness with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
10. INSTALL WIRE HARNESS CLAMP






(a) Install the 3 clamps and 3 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(b) Connect the wire harness with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
11. 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)
12. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

13. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Installation

14. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET Installation

15. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Installation

16. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR Installation

17. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR Installation

18. INSTALL FRONT FRAME ASSEMBLY Installation

19. INSTALL POWER STEERING LINK ASSEMBLY

20. INSTALL FRONT STABILIZER BAR

21. REMOVE ENGINE HANGERS Installation

22. INSTALL MANIFOLD STAY Installation

23. INSTALL STARTER ASSEMBLY

24. INSTALL ENGINE WIRE (for LHD) Installation

25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation

26. INSTALL VENTILATION HOSE Installation

27. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH

28. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation

30. CONNECT SUCTION HOSE SUB-ASSEMBLY

31. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

32. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

33. INSTALL FRONT AXLE ASSEMBLY LH

34. INSTALL FRONT AXLE ASSEMBLY RH Installation

35. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM LH

36. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM RH Installation

37. CONNECT TIE ROD ASSEMBLY LH

38. CONNECT TIE ROD ASSEMBLY RH

39. INSTALL FRONT SPEED SENSOR LH

40. INSTALL FRONT SPEED SENSOR RH Installation

41. INSTALL FRONT AXLE HUB NUT LH Installation

42. INSTALL FRONT AXLE HUB NUT RH Installation

43. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

44. INSTALL FRONT STABILIZER LINK ASSEMBLY RH Installation

45. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

46. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation

47. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation

48. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation

49. CONNECT ENGINE WIRE Installation

50. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation

51. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

52. CONNECT OIL COOLER OUTLET HOSE Installation

53. CONNECT OIL COOLER INLET HOSE Installation

54. CONNECT HEATER WATER INLET HOSE B Installation

55. CONNECT HEATER WATER OUTLET HOSE B Installation

56. INSTALL NO. 1 RADIATOR HOSE Installation

57. INSTALL NO. 2 RADIATOR HOSE Installation

58. CONNECT UNION TO CHECK VALVE HOSE Installation

59. CONNECT NO. 1 FUEL VAPOR FEED HOSE Installation

60. INSTALL ENGINE MOVING CONTROL ROD Installation

61. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation

62. INSTALL RESERVOIR BRACKET (for LHD) Installation

63. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD) Installation

64. INSTALL AIR CLEANER BRACKET Installation

65. INSTALL BATTERY Installation

66. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

67. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

68. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Installation

69. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

70. INSTALL NO. 1 AIR CLEANER INLET Installation

71. INSTALL NO. 2 AIR CLEANER INLET Installation

72. CONNECT VACUUM HOSES Installation

73. INSTALL V-RIBBED BELT Installation

74. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD) Installation

75. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

76. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

77. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

78. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

79. INSTALL FRONT WHEELS Installation

80. ADD ENGINE OIL Replacement

81. ADD ENGINE COOLANT Service and Repair

82. ADD AUTOMATIC TRANSAXLE FLUID
83. CHECK AUTOMATIC TRANSAXLE FLUID Procedures

84. INSPECT FOR FUEL LEAK Testing and Inspection

85. INSPECT FOR ENGINE OIL LEAK Replacement

86. INSPECT FOR COOLANT LEAK Testing and Inspection

87. INSPECT FOR EXHAUST GAS LEAK Installation

88. CHECK SHIFT LEVER POSITION On-Vehicle Inspection

89. CHECK AND ADJUST FRONT WHEEL ALIGNMENT Installation

90. CHECK IGNITION TIMING Engine

91. CHECK ENGINE IDLE SPEED Engine

92. CHECK CO/HC Engine

93. CHECK FUNCTION OF THROTTLE BODY ASSEMBLY On-Vehicle Inspection

94. INSTALL FRONT FENDER APRON SEAL LH Installation

95. INSTALL FRONT FENDER APRON SEAL RH Installation

96. INSTALL FRONT FENDER LINER LH

97. INSTALL FRONT FENDER LINER RH

98. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH

99. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH

100. INSTALL FLOOR UNDER COVER LH
101. INSTALL NO. 2 ENGINE UNDER COVER Installation

102. INSTALL NO. 1 ENGINE UNDER COVER Installation

103. INSTALL ENGINE UNDER COVER ASSEMBLY Installation

104. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

105. CHECK ABS SPEED SENSOR SIGNAL Installation

106. RESET MEMORY Installation
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