Installation
U660E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION
INSTALLATION
1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY
HINT: Testing and Inspection.
2. INSTALL 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 (0.40 in.) 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 fitting surface of the engine *1 and the converter fitting surface of the drive plate *2. (#)
(e) Using a vernier caliper and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in 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.
HINT: If a U660E is used with a 2GR-FE, the standard installation depth is 14 mm (0.551 in.) or more.
3. INSTALL NO. 1 OIL COOLER INLET HOSE
(a) Install the No. 1 oil cooler inlet hose.
4. INSTALL NO. 1 OIL COOLER OUTLET HOSE
(a) Install the No. 1 oil cooler outlet hose.
5. 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)
6. INSTALL WIRE HARNESS CLAMP BRACKET
(a) Install the 4 clamp brackets and 4 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
7. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the hole cover.
(b) Install the hole cover to the transaxle case with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
8. INSTALL TCM
(a) Install the TCM to the automatic transaxle assembly.
(b) Install and tighten the 2 bolts in the order shown in the illustration.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
9. INSTALL ENGINE MOUNTING FRONT BRACKET
(a) Install the engine mounting front bracket to the automatic transaxle with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle to the engine with the 11 bolts.
Bolt A - Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
Bolt B - Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
Bolt C - Torque: 46 Nm (469 kgf-cm, 34 ft-lbf)
Bolt D - Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)
NOTE: Make sure that the 2 knock pins are installed on the engine before installing the transaxle.
(b) Install the breather bracket to the camshaft housing sub-assembly LH with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
(c) Install the breather hose to the breather bracket.
11. CONNECT CONNECTOR
(a) Connect the park/neutral position switch connector.
12. INSTALL WIRE HARNESS
(a) Connect the wire harness with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
13. INSTALL ENGINE WIRE
14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
16. INSTALL FRONT FRAME ASSEMBLY Installation
17. INSTALL VANE PUMP ASSEMBLY Installation
18. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation
19. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
20. INSTALL GENERATOR ASSEMBLY Installation
21. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
22. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
(a) Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
Sealant:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the 6 torque converter clutch mounting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft-lbf)
NOTE: First install the black colored bolt, and then the remaining 5 bolts.
23. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
24. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation
25. INSTALL FRONT AXLE ASSEMBLY LH Installation
26. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Use the same procedures as described for the LH side.
27. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation
28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT: Use the same procedures as described for the LH side.
29. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation
30. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT: Use the same procedures as described for the LH side.
31. INSTALL FRONT SPEED SENSOR LH Installation
32. INSTALL FRONT SPEED SENSOR RH
HINT: Use the same procedures as described for the LH side.
33. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
34. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures as described for the LH side.
35. INSTALL FRONT AXLE SHAFT LH NUT Installation
36. INSTALL FRONT AXLE SHAFT RH NUT
HINT: Use the same procedures as described for the LH side.
37. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
38. INSTALL FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation
39. CONNECT STEERING GEAR OUTLET RETURN TUBE Installation
40. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE Installation
41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Install the transmission control cable assembly to the control shaft lever with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(b) Connect the transmission control cable assembly with a new clip to the No. 1 transmission control cable bracket.
42. CONNECT ENGINE WIRE Installation
43. INSTALL UPPER RELAY BLOCK COVER
44. INSTALL STARTER ASSEMBLY Installation
45. INSTALL ECM Installation
46. CONNECT HEATER WATER OUTLET HOSE A Installation
47. CONNECT HEATER WATER INLET HOSE A Installation
48. CONNECT NO. 1 OIL COOLER OUTLET HOSE Installation
49. CONNECT NO. 1 OIL COOLER INLET HOSE Installation
50. INSTALL RADIATOR HOSE OUTLET Installation
51. INSTALL RADIATOR HOSE INLET Installation
52. CONNECT FUEL TUBE SUB-ASSEMBLY Installation
53. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation
54. CONNECT NO. 1 FUEL VAPOR FEED HOSE Installation
55. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Installation
56. INSTALL NO. 1 AIR CLEANER INLET Installation
57. INSTALL AIR CLEANER CASE Installation
58. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE Installation
59. INSTALL NO. 2 AIR CLEANER INLET Installation
60. CONNECT VACUUM HOSES Installation
61. INSTALL ENGINE MOVING CONTROL ROD Installation
62. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation
63. INSTALL RADIATOR RESERVE TANK ASSEMBLY
64. INSTALL V-RIBBED BELT Installation
65. INSTALL BATTERY
66. INSTALL COWL TOP PANEL OUTER
67. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
68. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
69. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH Installation
70. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH Installation
71. INSTALL FRONT WHEELS Installation
72. ADD ENGINE COOLANT Service and Repair
73. ADD POWER STEERING FLUID
74. BLEED POWER STEERING SYSTEM Power Steering System
75. ADD AUTOMATIC TRANSAXLE FLUID
HINT: Procedures.
76. INSPECT SHIFT LEVER POSITION Adjustments
77. ADJUST SHIFT LEVER POSITION Adjustments
78. INSPECT FOR ENGINE COOLANT LEAK Service and Repair
79. INSPECT FOR FUEL LEAK Testing and Inspection
80. INSPECT FOR EXHAUST GAS LEAK
81. INSPECT IGNITION TIMING Engine
82. INSPECT ENGINE IDLE SPEED Engine
83. CHECK FUNCTION OF THROTTLE BODY On-Vehicle Inspection
84. INSTALL V-BANK COVER SUB-ASSEMBLY Installation
85. INSTALL COOL AIR INTAKE DUCT SEAL Installation
86. INSPECT CO/HC Engine
87. INSPECT ABS SPEED SENSOR SIGNAL
HINT: Test Mode Procedure.
88. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT: Service and Repair.
89. INSTALL FRONT FENDER APRON SEAL RH
90. INSTALL ENGINE UNDER COVER LH
91. INSTALL ENGINE UNDER COVER RH