Automatic Transaxle Assembly: Installation

1. Using vernier calipers and a straightedge, measure dimension "A" between the transaxle fitting part of the engine (1) and the converter fitting part of the drive plate (2).
   Fig 1: Measuring Dimension A

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2. 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.
   Fig 2: Aligning Matchmarks On Transaxle Case And Torque Converter Clutch Assembly

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3. 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°.

   Fig 3: Engaging Splines Of Stator Shaft And Stator

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4. 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.
   Fig 4: Aligning Matchmarks On Torque Converter Clutch Assembly And Transaxle Case

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5. Using vernier calipers and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (2)).

   Standard: 

   A + 1 mm (0.04 in.) or more 

   NOTE: Make sure to deduct the thickness of the straightedge.
   Fig 5: Measuring Dimension B

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1. Install the No. 1 oil cooler inlet hose.
   Fig 6: Identifying Oil Cooler Inlet Hose

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1. Install the No. 1 oil cooler outlet hose.
   Fig 7: Identifying Oil Cooler Outlet Hose

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1. Install the No. 1 transmission control cable bracket with the 2 bolts.

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

   Fig 8: Locating Transmission Control Cable Bracket Bolts

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1. Install the 4 clamp brackets and 4 bolts.

   Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

Fig 9: Identifying Wire Harness Clamp Brackets

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1. Coat a new O-ring with ATF, and install it to the hole cover.
2. Install the hole cover to the transaxle case with the bolt.

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

   Fig 10: Locating Speedometer Driven Hole Cover Bolt

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1. Install the TCM to the transaxle.
2. Install and tighten the 2 bolts in the order shown in the illustration.

   Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

   Fig 11: Identifying TCM

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1. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts.

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

   Fig 12: Locating Engine Mounting Bracket Bolts (Front)

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1. Apply clutch spline grease to the contact surface between the crankshaft (1) and torque converter centerpiece (2).

   Clutch spline grease: 

   Toyota Genuine Clutch Spline Grease, or equivalent 

   Maximum Amount: 1 g (0.0353 oz.) 

Fig 13: Identifying Clutch Spline Grease Application Points
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2. Keeping the engine and automatic transaxle assembly in a horizontal position, align the knock pins with each hole on the automatic transaxle assembly and tighten the 6 bolts shown in the illustration.

   Torque: 

   Bolt A 

   64 N*m (653 kgf*cm, 47 ft.*lbf) 

   Bolt B 

   46 N*m (469 kgf*cm, 34 ft.*lbf) 

   Bolt C 

   43 N*m (439 kgf*cm, 32 ft.*lbf) 

   Fig 14: Locating Automatic Transaxle Bolts

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   NOTE:

   • Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before transaxle installation.
   • Do NOT forcibly pry on the automatic transaxle assembly.
   • Check that the torque converter rotates.

1. Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.

   Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324, or equivalent 

1. Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
   Fig 15: Applying Adhesive To Mounting Bolt

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   Sealant

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

2. Install the 6 torque converter clutch mounting bolts.

   Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) 

   NOTE:

   First install the black colored bolt, and then the remaining 5 bolts.

Fig 16: Locating Torque Converter Clutch Setting Bolt
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1. Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts.
   Fig 17: Locating Flywheel Housing Under Cover Bolts

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   Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

Fig 20: Locating Steering Assembly Bolts

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Fig 21: Installing Front Suspension Member Brace Rears

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A 

Torque: 85 N*m (866 kgf*cm, 62 ft.*lbf) 

B 

Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

C 

Torque: 85 N*m (866 kgf*cm, 62 ft.*lbf) 

D 

Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

1. Install the clamp and connect the oil cooler inlet hose.
2. Install the clamp and connect the oil cooler outlet hose.

Fig 23: Locating Oil Cooler Hoses

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1. Install 2 new gaskets to the exhaust front pipe.
2. Install the exhaust front pipe to the exhaust manifolds with the 4 nuts.

   Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf) 

Fig 24: Locating Exhaust Pipe Bolts
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Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

Fig 25: Identifying Front Support Brackets And Nuts

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1. Coat the spline of the inboard joint shaft assembly with ATF.
   Fig 26: Installing Drive Shaft Assembly LH

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2. Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.
   NOTE:

   • Set the shaft snap ring with the opening side facing down.
   • Be careful not to damage the drive shaft dust cover, boot, or oil seal.
   • Move the drive shaft assembly while keeping it level.

1. Coat the spline of the inboard joint shaft assembly with ATF.
   Fig 27: Installing Bearing Bracket Hole Snap Ring

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2. Install the front drive shaft the assembly RH.
3. Using a screwdriver, install a new bearing bracket hole snap ring.
   NOTE:

   • Do not damage the boot or oil seal.
   • Move the drive shaft assembly while keeping it level.
4. Install a new bolt.

   Torque: 32 N*m (330 kgf*cm, 24 ft.*lbf) 

1. Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.
   Fig 28: Aligning Matchmarks

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   NOTE:

   Be careful not to damage the drive shaft boot and speed sensor rotor.

1. Install the lower ball joint to the front suspension lower No. 1 arm with the bolt and 2 nuts.
   Fig 29: Locating Front Suspension Arm Sub-Assembly Lower No 1 LH Bolt And Nuts

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   Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 

1. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.
   NOTE:

   • Be sure to perform this work for a new drive shaft.
   • Keep the threaded parts free of oil and foreign objects.
2. Using a socket wrench (30 mm), install a new axle hub nut.
   Fig 30: Staking Front Axle Hub LH Nut

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   Torque: 294 N*m (3,000 kgf*cm, 217 ft.*lbf) 

3. Using a chisel and hammer, stake the front axle hub nut.

Torque: 64 N*m (3,000 kgf*cm, 217 ft.*lbf) 

Fig 31: Locating Upper Bell Housing Bolts

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1. Install the clip and connect the transmission control cable assembly to the No. 1 transmission control cable bracket.
2. Connect the transmission control cable assembly to the control shaft lever.
3. Install the nut to the control shaft lever.
   Fig 32: Locating Transmission Cable Bracket Clip

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   Fig 33: Locating Transmission Control Cable Nut

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1. Install the starter assembly with the 2 bolts.
   Fig 34: Locating Starter Assembly Bolts

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   Torque: 37 N*m (380 kgf*cm, 28 ft.*lbf) 

2. Connect the wire harness to terminal 30 and install the nut. Then, attach the terminal cap.

   Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

3. Connect the terminal 50 connector to the starter assembly.

1. Connect the park/neutral position switch connector.
   Fig 35: Locating Park/Neutral Position Switch Connector

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1. Connect the wire harness with the bolt.

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

Fig 36: Locating Wire Harness Bolt

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Fig 37: Locating Body Bolts And Clamps

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Bolt A 

Torque: 12 N*m (123 kgf*cm, 9 ft.*lbf) 

Bolt B 

Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

Fig 38: Locating Breather Bracket Bolt

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1. Install the No. 1 air cleaner inlet with the bolt.
   Fig 39: Identifying No. 1 Air Cleaner Inlet And Bolt

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   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

1. Install the air cleaner case with the 3 bolts.
   Fig 40: Identifying Vacuum Hose And Hose Clamp

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   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

2. Connect the vacuum hose and hose clamp.

1. Install the air cleaner cap sub-assembly, and connect the 3 bands.
   Fig 41: Identifying Air Cleaner Cap Sub-Assembly

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2. Connect the mass air flow meter connector (^* 1).
   Fig 42: Identifying Mass Air Flow Meter Connector

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3. Connect the No. 2 ventilation hose (^* 2).
4. Connect the hose band (^* 3).
5. Connect the 2 vacuum hoses.
   Fig 43: Identifying Vacuum Hoses

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1. Install the No. 2 air cleaner inlet with the clamp and 2 bolts.
   Fig 44: Identifying Bolts, Clamp And Air Cleaner Inlet

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   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

Torque: 103 N*m (1,050 kgf*cm, 76 ft*lbf) 

1. Engage the 3 clips and install the V-bank cover.
   Fig 46: Identifying V-Bank Cover And Clips

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1. Install the battery and battery tray.
   Fig 47: Identifying Battery Bolts

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2. Install the battery clamp with the bolt and nut.

   Bolt 

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Nut 

   Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

1. Install the engine room side cover LH with the 6 clips.
   Fig 48: Identifying Hood Hinge Cover LH And Clips

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2. Install the hood hinge cover LH.

1. Install the engine room side cover RH with the 5 clips.
   Fig 49: Identifying Engine Room Side Cover RH And Clips

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   NOTE:

   When installing the engine room side cover RH, make sure that the engine coolant reservoir hose is positioned as shown in the illustration.

2. Install the hood hinge cover RH.

1. Install the intake duct seal with the 7 clips.
   Fig 50: Identifying Hood Hinge Cover LH And Clips

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1. Perform initialization procedure (See INITIALIZATION ).
   NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal.