Installation

U660E AUTOMATIC TRANSAXLE ASSEMBLY:

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 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 vernier calipers and a straightedge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (*1).






(e) Using vernier calipers and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (*1)).
Standard:
A + 1 mm (0.04 in.) or more
HINT: In the case of where a U660E is used with a 2GR-FE, the standard installation depth is 14 mm (0.55 in.) or more.
- 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.

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 transaxle.
(b) Install and tighten the 2 bolts in the order shown in the illustration.
Torque: 11 Nm (115 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)





(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. INSTALL STARTER ASSEMBLY Installation

12. CONNECT CONNECTOR





(a) Connect the park/neutral position switch connector.
13. INSTALL WIRE HARNESS





(a) Connect the wire harness with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
14. INSTALL ENGINE WIRE
15. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

16. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

17. INSTALL FRONT FRAME ASSEMBLY Installation

18. INSTALL VANE PUMP ASSEMBLY Installation

19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation

20. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

21. INSTALL GENERATOR ASSEMBLY Installation

22. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

23. 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.
Adhesive:
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.





(c) Install the flywheel housing under cover 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 described for the LH side.

27. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH Installation

28. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedures described for the LH side.

29. INSTALL TIE ROD ASSEMBLY LH Installation

30. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

31. INSTALL FRONT SPEED SENSOR LH Installation

32. INSTALL FRONT SPEED SENSOR RH
HINT: Use the same procedures 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 described for the LH side.

35. INSTALL FRONT AXLE HUB NUT LH Installation

36. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.

37. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation

38. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET Installation

39. CONNECT OIL RESERVOIR TO PUMP HOSE Installation

40. CONNECT RETURN TUBE SUB-ASSEMBLY Installation

41. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

42. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation

43. CONNECT ENGINE WIRE Installation

44. INSTALL RELAY BLOCK COVER UPPER
45. INSTALL ECM Installation

46. CONNECT HEATER INLET WATER HOSE Installation

47. CONNECT HEATER OUTLET WATER HOSE Installation

48. CONNECT NO. 1 OIL COOLER INLET HOSE Installation

49. CONNECT NO. 1 OIL COOLER OUTLET HOSE Installation

50. INSTALL RADIATOR HOSE INLET Installation

51. INSTALL RADIATOR HOSE OUTLET Installation

52. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE Installation

53. CONNECT NO. 1 FUEL VAPOR FEED HOSE Installation

54. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Installation

55. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation

56. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Installation

57. INSTALL BATTERY Installation

58. INSTALL NO. 1 AIR CLEANER INLET Installation

59. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

60. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

61. INSTALL AIR CLEANER INLET ASSEMBLY Installation

62. CONNECT VACUUM HOSES Installation

63. INSTALL V-RIBBED BELT Installation

64. INSTALL FRONT WHEELS Installation

65. ADD ENGINE OIL
66. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

67. ADD ENGINE COOLANT Testing and Inspection

68. ADD AUTOMATIC TRANSAXLE FLUID
HINT: Procedures

69. ADD POWER STEERING FLUID
70. BLEED POWER STEERING FLUID Service and Repair

71. CHECK FOR FUEL LEAKS Testing and Inspection

72. CHECK FOR ENGINE OIL LEAKS
73. CHECK FOR ENGINE COOLANT LEAKS Testing and Inspection

74. CHECK FOR EXHAUST GAS LEAKS
75. CHECK SHIFT LEVER POSITION On-Vehicle Inspection

76. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
HINT: Front Wheel Alignment

77. CHECK IGNITION TIMING Engine

78. CHECK ENGINE IDLE SPEED Engine

79. CHECK CO/HC Engine

80. CHECK FUNCTION OF THROTTLE BODY On-Vehicle Inspection

81. INSTALL FRONT FENDER APRON SEAL RH
82. INSTALL ENGINE UNDER COVER LH
83. INSTALL ENGINE UNDER COVER RH
84. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

85. INSTALL ENGINE ROOM SIDE COVER LH Installation

86. INSTALL ENGINE ROOM SIDE COVER RH Installation

87. INSTALL COOL AIR INTAKE DUCT SEAL Installation

88. CHECK ABS SPEED SENSOR SIGNAL
HINT: Test Mode Procedure

89. PERFORM TCM REGISTRATION
HINT: Registration

90. PERFORM INITIALIZATION
(a) Perform initialization procedure Repair Instruction - Initialization.
NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal.