Camry 2007

Transaxle Removal & Installation 1

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P311 Hybrid Transaxle



Specific to:

Toyota Camry 2007-2008


CAUTION
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. Make sure to turn the power switch off before removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Remove the luggage trim service hole cover.
  2.  
  3. Discharge the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the service plug grip. (Refer to service plug grip in Engine Electrical)
  8.  
  9. Place front wheels in the straight ahead position.
  10.  
  11. Remove the front wheels.
  12.  
  13. Remove the left and right engine under covers.
  14.  
  15. Remove the right front fender apron seal.
  16.  
  17. Drain the engine motor oil.
  18.  
  19. Drain the engine coolant.
  20.  
  21. Drain the HV inverter coolant.

    Click image to see an enlarged view

    Fig. Using a hexagon wrench (10 mm), remove the drain plug and drain inverter coolant

  22.  
  23. Drain the HV transaxle fluid.

    Click image to see an enlarged view

    Fig. Using a 10 mm socket hexagon wrench, remove the fill and drain plug.

  24.  
  25. Remove the right and left wiper arm assembly.
  26.  
  27. Remove the right and left fender cowl side seals.
  28.  
  29. Disengage the 4 claws and remove the cowl top ventilator louver sub-assembly.

    Click image to see an enlarged view

    Fig. Remove the cowl top ventilator louver sub-assembly

  30.  
  31. Remove the 4 bolts and the windshield wiper motor and link assembly.
  32.  
  33. Separate the master cylinder reservoir sub-assembly.
  34.  
  35. Remove the 4 bolts, 4 nuts and cowl top panel outer sub-assembly.
  36.  
  37. Remove the engine cover.
  38.  
  39. Remove the drive belt cover and drive belt.
  40.  
  41. Remove the air cleaner assembly.
  42.  
  43. Remove the inverter with converter assembly. (Refer to inverter with converter assembly in Engine Electrical)
  44.  
  45. Remove the HV water pump, hoses, electrical connector and brackets.

    Click image to see an enlarged view

    Fig. HV water pump, connectors and brackets shown

  46.  
  47. Remove the 4 bolts and inverter tray bracket.
  48.  
  49. Remove the 2 bolts and right side No. 2 engine mounting stay.
  50.  
  51. Remove the 3 bolts and the engine moving control rod with bracket.

    Click image to see an enlarged view

    Fig. Engine moving control rod with bracket shown

  52.  
  53. Remove the No 2. mounting bracket and ground cable.
  54.  
  55. Disconnect the radiator inlet and outlet hoses.
  56.  
  57. Disconnect the heater hoses.
  58.  
  59. Disconnect any remaining coolant hoses.
  60.  
  61. Remove the HV ECU mounting nuts.

    Click image to see an enlarged view

    Fig. HV control ECU and mounting nuts shown

  62.  
  63. Disconnect the 2 connectors and remove the hybrid vehicle control ECU.
  64.  
  65. Remove the bolt, 2 nuts, and the power steering ECU assembly.

    Click image to see an enlarged view

    Fig. Power steering ECU assembly shown

  66.  
  67. Disconnect the engine wire from the engine room relay block
  68.  
  69. Using a screwdriver, unlock the engine room R/B. Pull the engine room R/B upward.
  70.  
  71. Remove the 2 bolts and clamp from the body.
  72.  
  73. Remove the clamp from the bracket.
  74.  
  75. Release the lock lever of the connector as shown in the illustration.

    Click image to see an enlarged view

    Fig. Power steering ECU assembly shown

  76.  
  77. Remove the clip and nut, and separate the control lever. Disconnect the cable from the clamp.
  78.  
  79. Disconnect the fuel line.
  80.  
  81. Disconnect the 2 connectors from the A/C inverter compressor.
  82.  
  83. Disconnect all wiring harness clamps.
  84.  
  85. Remove the 3 mounting bolts of the A/C inverter compressor. Hang up the hoses instead of detaching them.
  86.  
  87. Remove the front exhaust pipe assembly.
  88.  
  89. Remove the left and right front axle nuts.
  90.  
  91. Remove the left and right stabilizer link assembly.
  92.  
  93. Remove the left and right speed sensor.
  94.  
  95. Disconnect the left and right tie rod ends.
  96.  
  97. Remove the bolt and 2 nuts, and separate the left and right front suspension lower No. 1 arm from the lower ball joint.
  98.  
  99. Separate the left and right drive axles from the steering knuckle.
  100.  
  101. Remove the No.1 exhaust pipe support bracket.
    WARNING
    Secure the steering wheel with the seat belt in order to prevent rotation. This operation is useful to prevent damage to the spiral cable.

  102.  
  103. Put matchmarks on the steering intermediate shaft assembly and the power steering link assembly.
  104.  
  105. Remove the bolt and separate the steering intermediate shaft assembly from the power steering link assembly.
  106.  
  107. Remove the engine assembly with transaxle as follows:
    1. Secure the engine lifter.
    2.  
    3. Remove the 4 bolts, 2 nuts and frame side rail plate right and left.
    4.  
    5. Remove the 4 bolts, 2 nuts and front suspension member brace rear right and left.
    6.  
    7. Carefully remove the engine assembly from the vehicle.
    8.  
    9. Install the 2 engine hangers as shown in the illustration.

      Click image to see an enlarged view

      Fig. Install the 2 engine hangers as shown

    10.  
    11. Using a chain block and an engine sling device, hang the engine assembly.
    12.  
    13. Remove the bolt and transaxle mass damper.

      Click image to see an enlarged view

      Fig. The bolt and transaxle mass damper shown

    14.  

  108.  
  109. Remove the front assembly as follows:
    1. Remove the 2 nuts and separate the right and left engine mounting insulators.

      Click image to see an enlarged view

      Fig. Engine mounting insulators right and left shown

    2.  
    3. Remove the bolt from the front engine mounting insulator.
    4.  
    5. Raise the engine assembly and separate the front frame.
    6.  

  110.  
  111. Remove the left and right axle shaft assembly.
  112.  
  113. Remove the engine wire.
  114.  
  115. Separate the transaxle from the engine as follows:
    1. Remove the flywheel housing under cover from the hybrid vehicle transaxle assembly.
    2.  
    3. Remove the bolt and ground wire.
    4.  
    5. Disconnect the wire harnesses from the clamps.
    6.  
    7. Disconnect the connectors.

      Click image to see an enlarged view

      Fig. HV Transaxle connector view

    8.  
    9. Remove the 3 bolts and 3 clamps.
    10.  
    11. Remove all 3 transaxle control cable brackets.
    12.  
    13. Remove the bolt from the hybrid transaxle.
    14.  
    15. Disconnect the 3 wire harness clamps from the automatic transmission case cover.
    16.  
    17. Remove the 2 bolts, and bracket from the hybrid transaxle.
    18.  
    19. Remove the transmission case cover.
    20.  
    21. Remove the 2 bolts, clip, and automatic transmission case cover from the hybrid transaxle.

      Click image to see an enlarged view

      Fig. Automatic transaxle case cover shown

    22.  
    23. Remove the HV transaxle mass damper and gasket.
    24.  
    25. Remove the 2 transmission oil pump cover plugs and 2 O-rings.
    26.  
    27. Disconnect the water hose from the hybrid transaxle
    28.  
    29. Remove the 3 bolts and engine mounting bracket.
    30.  
    31. Remove the 9 bolts. Separate and remove the hybrid vehicle transaxle.
      WARNING
      Do not pry between the transaxle assembly and engine more than necessary to prevent the knock pin from being damaged.

    32.  

  116.  

To install:

  1. Make sure that the knock pins are installed on the engine.
  2.  
  3. Install the hybrid vehicle transaxle and the 9 bolts shown in the illustration to the engine as follows:

    Bolt A - Torque: 47 ft. lbs. (64 Nm)
     
    Bolt B - Torque: 34 ft. lbs. (46Nm)
     
    Bolt C - Torque: 21 ft. lbs. (28 Nm)
     
    Bolt D - Torque: 33 ft. lbs. (44 Nm)

    Click image to see an enlarged view

    Fig. Automatic transaxle bolt tightening positions

     

  4.  
  5. Install the front engine mounting bracket with the 3 bolts. Tighten to 47 ft. lbs. (64 Nm)
  6.  
  7. Install the water hose with the clamp.
  8.  
  9. Install 2 new O-rings and the 2 transmission oil pump cover plugs. Tighten to 20 ft. lbs. (27 Nm)
  10.  
  11. Install a new gasket and the HV transaxle mass damper. Tighten to 29 ft. lbs. (39 Nm)
  12.  
  13. Install the automatic transmission case cover with the 2 bolts and clip. Tighten the bolts to 62 inch. lbs. (7 Nm)
  14.  
  15. Install the transmission case cover and tighten the bolts to 71 inch. lbs. (8 Nm)
  16.  
  17. Connect the wire harness with the bolt and 3 clamps. Tighten the bolts to 71 inch. lbs. (8 Nm)
  18.  
  19. Install the hybrid inverter protector and the all 3 transaxle control cable brackets. Tighten to 7 ft. lbs. (10 Nm)
  20.  
  21. Install the 3 wire harness brackets with the 3 bolts. Tighten the bolts to 74 inch. lbs. (8.4 Nm)
  22.  
  23. Connect the connectors.
  24.  
  25. Connect the wire harnesses to the wire harness clamps.
  26.  
  27. Install the ground wire with the bolt. Tighten to 9 ft. lbs. (12 Nm)
  28.  
  29. Install the flywheel housing under cover to the hybrid vehicle transaxle assembly.
  30.  
  31. Install the left and right drive axles.
  32.  
  33. Install the front frame assembly.
  34.  
  35. Install the dynamic damper.
  36.  
  37. Install the engine mounting insulators right and left with the 2 nuts. Tighten to 70 ft. lbs. (95 Nm)
  38.  
  39. Install the engine front mounting insulator and bolt. Tighten to 64 ft. lbs. (87 Nm)
  40.  
  41. Install the bolt and transaxle mass damper tighten to 10 ft. lbs. (14 Nm)
  42.  
  43. Set the engine assembly with transaxle on the engine lifter.
  44.  
  45. Install the engine assembly to the vehicle.
  46.  
  47. Install the frame side plate left and right with the 4 bolts and 2 nuts.
  48.  
  49. Bolt A - Torque: to 63 ft. lbs. (85 Nm)
  50.  
  51. Bolt B - Torque: bolt and nut to 24 ft. lbs. (32 Nm)

    Click image to see an enlarged view

    Fig. The frame side plate right and left with the 4 bolts and 2 nuts shown

  52.  
  53. Install the front suspension member rear right and left brace with the 4 bolts and 2 nuts.
  54.  
  55. Bolt C - Torque: 63 ft. lbs. (85 Nm)
  56.  
  57. Bolt B - Torque: bolt and nut Install the stabilizer link assembly with the nut.
  58.  
  59. Install the steering intermediate shaft assembly.
  60.  
  61. Install the No.1 exhaust support bracket. Tighten the 2 mounting bolts to 14 ft. lbs. (19 Nm)
  62.  
  63. Install the left and right axle assembly into steering knuckle.
  64.  
  65. Install the right and left front suspension lower arm and tighten nuts and bolts to 44 ft. lbs. (75 Nm)
  66.  
  67. Install the tie rod end sub-assembly to the steering knuckle with the nut. Tighten to 36 ft. lbs. (49 Nm)
  68.  
  69. Install a new cotter pin.
  70.  
  71. Install the front speed sensors to the steering knuckle with the bolt. Tighten the bolts to 71 inch. lbs. (8 Nm)
  72.  
  73. Install the stabilizer link assembly with the nut and tighten to 55 ft. lbs. (74 Nm)
  74.  
  75. Tighten the new axle assembly nut to 217 ft. lbs. (294 Nm)
  76.  
  77. Using a chisel and hammer, stake the front axle hub nuts.
  78.  
  79. Install the front exhaust pipe assembly and tighten to 46 ft. lbs (62 Nm).
  80.  
  81. Install the A/C inverter compressor and tighten to 18 ft. lbs. (25 Nm).
  82.  
  83. Connect the No. 4 engine wire clamps.
  84.  
  85. Connect the A/C inverter compressor 2 connectors. Lock the green-colored lock.
  86.  
  87. Install the fuel line. Check if the pipe and the connector are securely connected by trying to pull them apart. Install the fuel line clamp.
  88.  
  89. Install the transmission control cable assembly to the transaxle. Tighten the control lever nut to 9 ft. lbs. (13 Nm).
  90.  
  91. Install the 2 bolts and power steering wire to the power steering link assembly.
  92.  
  93. Connect the 3 wire harness connectors to the power steering link assembly and securely lock the connector.
  94.  
  95. Connect the clamp to the bracket.
  96.  
  97. Install the 2 bolts and clamp the grounds to the body. Tighten to 74 inch. lbs. (8 Nm)
  98.  
  99. Connect the 3 connectors and 2 clamps to the engine room junction block.
  100.  
  101. Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors.
  102.  
  103. Install the power steering ECU assembly. Tighten the mounting bolts to 75 inch. lbs. (8.4 Nm)
  104.  
  105. Connect the 2 power steering ECU assembly connectors.
  106.  
  107. Connect the connector and install the hose clamp to the power steering ECU assembly.
  108.  
  109. Install the hybrid vehicle control ECU with the 3 nuts. Tighten the nuts to 49 inch. lbs. (5.5 Nm)
  110.  
  111. Install the cowl top panel outer sub-assembly with the 4 bolts and 4 nuts
  112.  
  113. Reconnect the heater hoses.
  114.  
  115. Reconnect the radiator inlet and outlet hoses.
  116.  
  117. Install the 3 bolts and No. 2 right engine mounting bracket. Tighten the bolts to 38 ft. lbs. (52 Nm)
  118.  
  119. Install the ground cable with the bolt and tighten to 75 inch. lbs. (8.4 Nm)
  120.  
  121. Install the engine moving control rod by tightening the 3 bolts in the order shown in the illustration.
  122.  
  123. Tightening the control rod mounting bolts to bolts 47 ft. lbs. (64 Nm)

    Click image to see an enlarged view

    Fig. Tighten the 3 bolts in the order shown

  124.  
  125. Install the No. 2 right engine mounting stay with the 2 bolts. Tighten to 47 ft. lbs. (64 Nm)
  126.  
  127. Install the HV water pump with motor and bracket assembly with the bolt and 2 nuts. Tighten to 7 ft. lbs. (10 Nm)
  128.  
  129. Connect the water pump electrical connector.
  130.  
  131. Reconnect the water hose to the HV electrical water pump.
  132.  
  133. Install the inverter tray bracket with the 4 bolts and tighten to 71 inch. lbs. (8 Nm)
  134.  
  135. Install the inverter with converter assembly.
  136.  
  137. Install the air cleaner case with the 3 bolts. Tighten to 44 inch. lbs. (5 Nm)
  138.  
  139. Connect the hose clamp.
  140.  
  141. Install the air cleaner cap assembly.
  142.  
  143. Install the air cleaner inlet with the 2 bolts. Tighten to 44 inch. lbs. (5 Nm)
  144.  
  145. Install the drive belt and belt cover.
  146.  
  147. Install the cowl top panel outer sub-assembly with the 4 bolts and 4 nuts
  148.  
  149. Install the master cylinder reservoir sub-assembly.
  150.  
  151. Install the windshield wiper motor and link assembly with the 4 bolts
  152.  
  153. Engage the 4 claws and install the cowl top ventilator louver sub-assembly.
  154.  
  155. Engage the claw and install the left and right front fender to cowl side seal.
  156.  
  157. Install the front left and right wiper arm and blade assembly. Tighten the nut to 15 ft. lbs. (20 Nm)
  158.  
  159. Install the front wheels.
  160.  
  161. Install new engine motor oil.
  162.  
  163. Install the service plug grip.
  164.  
  165. Connect the negative battery cable.
  166.  
  167. Install the luggage trim service hole cover
  168.  
  169. Add engine coolant for the engine.
  170.  
  171. Add coolant for the inverter.
  172.  
  173. Add and inspect HV transaxle fluid.
  174.  
  175. Check the vehicle for leaks.
  176.  
  177. Check for correct shift lever position.
  178.  
  179. Adjust the front wheel alignment.
  180.  
  181. Check the ignition timing and idle speed.
  182.  
  183. Check the emissions CO/HC.
  184.  
  185. Install the right front fender apron.
  186.  
  187. Install the left and right under engine covers.
  188.  
  189. Install the engine cover assembly.
  190.  
  191. Check the ABS sensors for proper operation.
  192.  
  193. Perform initialization procedures.
  194.  

U250E Automatic Transaxle



Specific to:

Toyota Camry 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Place front wheels facing straight ahead.
  6.  
  7. Remove front wheels.
  8.  
  9. Remove both engine under covers.
  10.  
  11. Remove RH front fender apron seal.
  12.  
  13. Drain and recycle the engine coolant.
  14.  
  15. Drain automatic transaxle fluid. Using a 6 mm socket hexagon wrench, remove the drain plug and gasket, and drain ATF. Install a new gasket and drain plug. Tighten the drain plug to 36 ft. lbs. (49 Nm).
  16.  
  17. Remove windshield wiper link assembly.
  18.  
  19. Remove cowl top panel outer sub-assembly.
  20.  
  21. Remove No. 1 engine cover sub-assembly.
  22.  
  23. Remove the drive belt.
  24.  
  25. Remove air cleaner inlet assembly.
  26.  
  27. Remove air cleaner cap sub-assembly.
  28.  
  29. Remove air cleaner case sub-assembly.
  30.  
  31. Remove battery.
  32.  
  33. Remove RH No. 2 engine mounting stay.
  34.  
  35. Remove engine moving control rod sub-assembly.
  36.  
  37. Remove RH No. 2 engine mounting bracket.
  38.  
  39. Disconnect No. 1 vacuum hose connector.
  40.  
  41. Disconnect radiator hose inlet.
  42.  
  43. Disconnect radiator hose outlet.
  44.  
  45. Disconnect oil cooler inlet hose.
  46.  
  47. Disconnect oil cooler outlet hose.
  48.  
  49. Disconnect heater inlet water hose.
  50.  
  51. Disconnect heater outlet water hose.
  52.  
  53. Remove ECM.
  54.  
  55. Disconnect engine wire.
  56.  
  57. Disconnect transmission control cable assembly by performing the following:
    1. Remove the nut from the control shaft lever.
    2.  
    3. Disconnect the transmission control cable assembly from the control shaft lever.
    4.  
    5. Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.
    6.  
    7. Disconnect the transmission control cable assembly from the control cable clamp.
    8.  

  58.  
  59. Disconnect No. 1 oil reservoir to pump hose.
  60.  
  61. Disconnect return tube sub-assembly.
  62.  
  63. Disconnect fuel tube sub-assembly.
  64.  
  65. Remove generator assembly.
  66.  
  67. Separate compressor and magnetic clutch.
  68.  
  69. Remove front exhaust pipe assembly.
  70.  
  71. Remove both front axle hub nut.
  72.  
  73. Remove both front stabilizer link assemblies.
  74.  
  75. Remove both front speed sensors.
  76.  
  77. Disconnect both tie rod assemblies.
  78.  
  79. Disconnect both front suspension lower No. 1 arms.
  80.  
  81. Separate both front axle assemblies
  82.  
  83. Remove drive plate and torque converter clutch setting bolt by performing the following:
    1. Remove the flywheel housing under cover.
    2.  
    3. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.
      NOTE
      There will be one green colored bolt.

    4.  

  84.  
  85. Separate steering sliding yoke.
  86.  
  87. Remove engine assembly with transaxle.
  88.  
  89. Remove vane pump assembly.
  90.  
  91. Remove front frame assembly.
  92.  
  93. Remove both front drive shaft assembly.
  94.  
  95. Remove engine wire.
  96.  
  97. Remove starter assembly.
  98.  
  99. Remove the 3 bolts and engine mounting front bracket.
  100.  
  101. Separate automatic transaxle assembly by performing the following:
    1. Remove the 5 bolts
    2.  
    3. Remove the 4 lower side mounting bolts.
    4.  
    5. Separate and remove the automatic transaxle.

      Click image to see an enlarged view

      Fig. Removing 5 bolts-U250E A/T



      Click image to see an enlarged view

      Fig. Removing 4 lower mounting bolts-U250E A/T

    6.  

  102.  
  103. Remove torque converter clutch assembly.
  104.  
  105. Remove speedometer driven hole cover sub-assembly by performing the following:
    1. Remove the bolt and hole cover from the transaxle case
    2.  
    3. Remove the O-ring from the hole cover
    4.  

  106.  
  107. Remove the bolt and No. 2 transmission control cable bracket
  108.  
  109. Disconnect the wire harnesses from the 2 brackets. Remove the 2 bolts and 2 clamps.
  110.  
  111. Remove the bolt and disconnect the wire harness.
  112.  
  113. DISCONNECT transmission electrical CONNECTORS by performing the following:
    1. Disconnect the transmission wire connector.
    2.  
    3. Disconnect the park/neutral position switch connector.
    4.  
    5. Disconnect the 2 speed sensor connectors.

      Click image to see an enlarged view

      Fig. Disconnecting transmission connectors-U250E A/T

    6.  

  114.  
  115. Remove no. 1 transmission control cable bracket by performing the following:
    1. Remove the bolt and oil cooler tube clamp.
    2.  
    3. Remove the 2 bolts and No. 1 transmission control cable bracket.
    4.  

  116.  
  117. Remove transmission oil filler tube sub-assembly by performing the following:
    1. Remove the bolt and transmission oil filler tube sub-assembly.
    2.  
    3. Remove the O-ring from the oil filler tube sub-assembly.
    4.  

  118.  
  119. Using SST 09023-12701 and a wrench, disconnect the No. 1 oil cooler inlet tube.
  120.  
  121. Using SST 09023-12701and a wrench, disconnect the No. 1 oil cooler outlet tube.
  122.  
  123. Remove the 3 bolts and transaxle case upper cover.

    Click image to see an enlarged view

    Fig. Removing 3 bolts and transaxle case upper cover-U250E A/T

  124.  

To install:

  1. Install the transmission case upper cover with the 3 bolts and tighten to: 8 ft. lbs. (12 Nm).
  2.  
  3. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts and tighten to 47 ft. lbs. (64 Nm).
  4.  
  5. Coat a new O-ring with ATF, and install it to the oil filler tube. Install the oil filler tube to the automatic transaxle with the bolt and tighten to 49 inch lbs. (6 Nm).
  6.  
  7. Install the ATF level gauge.
  8.  
  9. Install the No. 1 control cable bracket with the 2 bolts and tighten to 9 ft. lbs. (12 Nm).
  10.  
  11. Install No. 1 oil cooler inlet tube by performing the following:
    1. Temporarily install the No. 1 oil cooler outlet tube.
    2.  
    3. Temporarily install the No. 1 oil cooler inlet tube.
    4.  
    5. Install the oil cooler tube clamp with the bolt and tighten 48 inch lbs. (5 Nm).
    6.  
    7. Using Special Tool: 09023-12701 and a wrench, tighten the No. 1 oil cooler inlet tube to 25 ft. lbs. (34 Nm).
      NOTE
      Use a torque wrench with a fulcrum length of 13.58 inches (345 mm).

    8.  

  12.  
  13. Using Special Tool: 09023-12701 and a wrench, tighten the No. 1 oil cooler outlet tube to 25 ft. lbs. (34 Nm).
    NOTE
    Use a torque wrench with a fulcrum length of 13.58 inches (345 mm).

  14.  
  15. Connect the transmission wire connector. Connect the park/neutral position switch connector. Connect the 2 speed sensor connectors.
  16.  
  17. Connect the wire harness with the bolt and tighten to 9 ft. lbs. (12 Nm).
  18.  
  19. Install the wire harness 2 brackets with the 2 bolts and tighten to 74 inch lbs. (8.4 Nm). Connect the wire harnesses to the clamps.
  20.  
  21. Install the No. 2 transmission control cable bracket with the bolt and tighten 9 ft. lbs. (12 Nm).
  22.  
  23. Coat a new O-ring with ATF WS, and install speedometer driven hole cover sub-assembly to the hole cover and tighten to 47 inch lbs. (6 Nm).
  24.  
  25. Install the torque converter clutch assembly, as follows:
    1. 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.

      Click image to see an enlarged view

      Fig. Measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate

    2.  
    3. Set the key of the front oil pump drive gear to the top and put a mark on the housing.

      Click image to see an enlarged view

      Fig. Setting the key of the front oil pump drive gear

    4.  
    5. Put a mark on the torque converter clutch so that its groove can be clearly indicated.
    6.  
    7. Align the 2 marks on the transaxle case and torque converter clutch and fit the splined part of the input shaft to the spline part of the turbine runner.
    8.  
    9. Rotating the torque converter clutch, fit the spline part of the stator shaft to the spline part of the stator. Rotate it about 180°.
      CAUTION
      When rotating the torque converter clutch, do not push it with excessive force.

    10.  
    11. Rotating the torque converter clutch, align the 2 marks on the case and the torque converter clutch again and fit the key of the oil pump drive gear into the key way of the torque converter clutch.
    12.  
    13. Using vernier calipers and a straight edge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in previous steps) -A- + 1 (0.04 in.) mm or more. Remember to minus the thickness of the straight edge.

      Click image to see an enlarged view

      Fig. Measuring dimension "B"

    14.  

  26.  
  27. Install the automatic transaxle assembly, as follows:
    1. Install the automatic transaxle to the engine with the 5 bolts:

      Bolt A: 47 ft. lbs. (64 Nm)
       
      Bolt B: 34 ft. lbs. (46 Nm)
       
      Bolt C: 34 ft. lbs. (46 Nm)

      Click image to see an enlarged view

      Fig. Automatic transaxle bolt tightening sequence

       

    2.  
    3. Install the 4 lower side mounting bolts and tighten to 32 ft. lbs. (44 Nm).
    4.  

  28.  
  29. Install starter assembly.
  30.  
  31. Install engine wire.
  32.  
  33. Install front drive shaft assembly.
  34.  
  35. Install front frame assembly.
  36.  
  37. Install vane pump assembly.
  38.  
  39. Install engine assembly with transaxle.
  40.  
  41. Install steering sliding yoke.
  42.  
  43. Install the drive plate and torque converter clutch setting bolt, as follows:
    1. Apply a few drops of adhesive (Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent) to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
    2.  
    3. Install the 6 torque converter clutch mounting bolts and tighten to 30 ft. lbs. (41 Nm). First install the black colored bolt, and then the remaining 5 bolts.
    4.  
    5. Install the flywheel housing under cover.
    6.  

  44.  
  45. To complete installation, reverse removal procedure.
  46.  
  47. Tighten control shaft lever nut to 11 ft. lbs. (15 Nm).
  48.  
  49. Add engine coolant.
  50.  
  51. Add automatic transaxle fluid (Toyota Genuine ATF WS).
  52.  
  53. Add power steering fluid.
  54.  
  55. Bleed power steering fluid.
  56.  
  57. Inspect automatic transaxle fluid.
  58.  
  59. Check for fuel leaks.
  60.  
  61. Check for engine coolant leaks.
  62.  
  63. Check for exhaust gas leaks.
  64.  
  65. Check for shift lever position.
  66.  
  67. Adjust shift lever position.
  68.  
  69. Inspect and adjust front wheel alignment.
  70.  
  71. Check ignition timing.
  72.  
  73. Check engine idle speed.
  74.  
  75. Inspect CO/HC.
  76.  
  77. Check abs speed sensor signal.
  78.  

 
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