Installation

U151F 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 TRANSFER ASSEMBLY
HINT: Installation

3. 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)
4. INSTALL TRANSFER STIFFENER PLATE RH






(a) Install the transfer stiffener plate RH with 5 bolts to the transfer and engine mounting bracket RR.
Torque: 34 Nm (350 kgf-cm, 25 ft-lbf)
5. 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)
6. 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)
7. 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)
8. 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)
9. 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)
10. CONNECT BREATHER PLUG HOSE






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






(a) Connect the transmission wire connector.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 transmission revolution sensor connectors.
12. INSTALL STARTER ASSEMBLY

13. CONNECT WIRE HARNESS






(a) Connect the wire harness with the bolt.
Torque: 19 Nm (193 kgf-cm, 14 ft-lbf)
14. 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.
15. 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)
16. INSTALL MANIFOLD STAY Installation

17. INSTALL ENGINE WIRE
18. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

19. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

20. INSTALL FRONT FRAME ASSEMBLY Installation

21. INSTALL POWER STEERING LINK

22. INSTALL FRONT STABILIZER BAR

23. INSTALL VANE PUMP ASSEMBLY Installation

24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation

25. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

26. INSTALL GENERATOR ASSEMBLY

27. INSTALL HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT LH (w/ Air Suspension) Installation

28. INSTALL HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT RH (w/ Air Suspension) Installation

29. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

30. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation

31. INSTALL FRONT AXLE ASSEMBLY LH Installation

32. INSTALL FRONT AXLE ASSEMBLY RH Installation

33. INSTALL NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH Installation

34. INSTALL NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER RH Installation

35. INSTALL TIE ROD ASSEMBLY LH Installation

36. INSTALL TIE ROD ASSEMBLY RH Installation

37. INSTALL FRONT SPEED SENSOR LH Installation

38. INSTALL FRONT SPEED SENSOR RH Installation

39. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

40. INSTALL FRONT STABILIZER LINK ASSEMBLY RH Installation

41. INSTALL FRONT AXLE HUB NUT LH Installation

42. INSTALL FRONT AXLE HUB NUT RH Installation

43. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation

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

45. INSTALL OXYGEN SENSOR Installation

46. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY Installation

47. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSEMBLY Installation

48. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE Installation

49. CONNECT RETURN TUBE SUB-ASSEMBLY Installation

50. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

51. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation

52. CONNECT ENGINE WIRE Installation

53. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

54. INSTALL JUNCTION BLOCK COVER
55. CONNECT HEATER INLET WATER HOSE Installation

56. CONNECT HEATER OUTLET WATER HOSE Installation

57. CONNECT OIL COOLER INLET HOSE Installation

58. CONNECT OIL COOLER OUTLET HOSE Installation

59. INSTALL RADIATOR HOSE INLET Installation

60. INSTALL RADIATOR HOSE OUTLET Installation

61. CONNECT UNION TO CHECK VALVE HOSE Installation

62. CONNECT NO. 1 FUEL VAPOR FEED HOSE Installation

63. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Installation

64. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation

65. INSTALL AIR CLEANER BRACKET Installation

66. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Installation

67. INSTALL BATTERY Installation

68. INSTALL NO. 1 AIR CLEANER INLET Installation

69. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

70. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

71. INSTALL NO. 2 AIR CLEANER INLET Installation

72. CONNECT VACUUM HOSES Installation

73. INSTALL V-RIBBED BELT Installation

74. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation

75. INSTALL WINDSHIELD WIPER LINK ASSEMBLY Installation

76. INSTALL FRONT WHEELS Installation

77. ADD ENGINE OIL
78. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

79. ADD ENGINE COOLANT Testing and Inspection

80. ADD AUTOMATIC TRANSAXLE FLUID
81. ADD POWER STEERING FLUID
82. BLEED POWER STEERING FLUID

83. CHECK FOR FUEL LEAKS Testing and Inspection

84. CHECK FOR ENGINE OIL LEAKS
85. CHECK FOR ENGINE COOLANT LEAKS Testing and Inspection

86. CHECK FOR EXHAUST GAS LEAKS
87. INSPECT SHIFT LEVER POSITION Adjustments

88. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

89. INSPECT IGNITION TIMING Engine

90. INSPECT ENGINE IDLE SPEED Engine

91. INSPECT CO/HC Engine

92. INSPECT THROTTLE BODY On-Vehicle Inspection

93. INSTALL FRONT FENDER APRON SEAL RH
94. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
95. INSTALL NO. 2 ENGINE UNDER COVER (w/ No. 2 engine under cover)
96. INSTALL NO. 1 ENGINE UNDER COVER
97. INSTALL ENGINE UNDER COVER ASSEMBLY (w/ engine under cover assembly)
98. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

99. INSTALL ENGINE ROOM COVER SIDE Installation

100. INSTALL COOL AIR INTAKE DUCT SEAL Installation

101. CHECK ABS SPEED SENSOR SIGNAL

102. RESET MEMORY
Programming and Relearning

103. PREFORM INITIALIZATION
HINT: Some systems need initialization after reconnecting the cable to the negative battery terminal Repair Instruction - Initialization.