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Installation (To 12/2010): Installation

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY 

    HINT: 

    Refer to INSPECTION .

  2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
    1. Engage the splines of the input shaft and turbine runner.
      Fig 1: Engaging Splines Of Input Shaft And Turbine Runner
      GTY252469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.
      Fig 2: Engaging Splines Of Stator Shaft And Stator
      GTY250895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If the stator shaft splines are difficult to engage with the stator splines, move the torque converter back approximately 10 mm (0.394 in.) and engage the splines while rotating the torque converter.

    3. 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.
      Fig 3: Engaging Key Of Oil Pump Drive Gear Into Slot On Torque Converter Clutch Assembly
      GTY252470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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. (#)
      Fig 4: Identifying Dimension "A" Between Transaxle Fitting Surface Of Engine*1
      GTY205452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a vernier caliper and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A", which was measured in step (#).
      Fig 5: Identifying Dimension "B"
      GTY248322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard

      A + 1 mm (0.0394 in.) or more

      NOTE:
      • 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 
    1. Install the No. 1 oil cooler inlet hose.
      Fig 6: Identifying Oil Cooler Inlet Hose
      GTY126859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 1 OIL COOLER OUTLET HOSE 
    1. Install the No. 1 oil cooler outlet hose.
      Fig 7: Identifying Oil Cooler Outlet Hose
      GTY111755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 1 transmission control cable bracket with the 2 bolts.
      Fig 8: Locating No. 1 Transmission Control Cable Bracket Bolts
      GTY130710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  6. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the 4 clamp brackets and 4 bolts.
      Fig 9: Identifying Bolts And Clamp Brackets
      GTY126651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    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.
      Fig 10: Locating Hole Cover To Transaxle Case With Bolt
      GTY135217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  8. INSTALL TCM 
    1. Install the TCM to the automatic transaxle assembly.
      Fig 11: Identifying TCM
      GTY308214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install and tighten the 2 bolts in the order shown in the illustration.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

  9. INSTALL ENGINE MOUNTING FRONT BRACKET 
    1. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts.
      Fig 12: Locating Bolts And Engine Mounting
      GTY202012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Confirm that 2 knock pins are on the transaxle contact surface of the engine cylinder block before transaxle installation.
      Fig 13: Identifying Knock Pins Are On Transaxle Contact Surface Of Engine Cylinder Block
      GTY301173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Knock Pin
      *2 Crankshaft
    2. Apply clutch spline grease to the round of the crankshaft contact surface (A) with the torque converter centerpiece.

      Clutch spline grease

      Toyota Genuine Clutch Spline Grease or equivalent

      Maximum spread

      Approximately 1g (0.0353 oz.)

    3. Install the automatic transaxle to the engine with the 11 bolts.
      Fig 14: Locating Automatic Transaxle Bolts
      GTY301053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt A 

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

      Bolt B 

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

      Bolt C 

      Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf) 

      Bolt D 

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

    4. Install the breather bracket to the camshaft housing sub-assembly LH with the bolt.
      Fig 15: Locating Breather Bracket Bolt
      GTY124035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    5. Install the breather hose to the breather bracket.
  11. CONNECT CONNECTOR 
    1. Connect the park/neutral position switch connector.
      Fig 16: Locating Park/Neutral Position Switch Connector
      GTY124434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WIRE HARNESS 
    1. Connect the wire harness with the bolt.
      Fig 17: Locating Wire Harness Bolt
      GTY131635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  13. INSTALL ENGINE WIRE 
  14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  . Refer to INSTALLATION - Step 1
  15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  . Refer to INSTALLATION - Step 2
  16. INSTALL FRONT FRAME ASSEMBLY  . Refer to INSTALLATION - Step 29
  17. INSTALL VANE PUMP ASSEMBLY  . Refer to INSTALLATION - Step 30
  18. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE  . Refer to INSTALLATION - Step 31
  19. INSTALL COOLER COMPRESSOR ASSEMBLY  . Refer to INSTALLATION - Step 32
  20. INSTALL GENERATOR ASSEMBLY  . Refer to INSTALLATION - Step 1
  21. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY  . Refer to INSTALLATION - Step 9
  22. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
      Fig 18: Applying Adhesive To Torque Converter Clutch Mounting Bolts
      GTY307641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the 6 torque converter clutch mounting bolts.
      Fig 19: Locating Torque Converter Clutch Setting Bolt
      GTY131830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 41 N*m (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 
    1. Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts.
      Fig 20: Locating Flywheel Housing Under Cover Bolts
      GTY135623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  24. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET  . Refer to INSTALLATION - Step 37
  25. INSTALL FRONT AXLE ASSEMBLY LH  . Refer to INSTALLATION - Step 3
  26. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT: 

    Use the same procedure as described for the LH side.

  27. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  . Refer to INSTALLATION - Step 4
  28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as described for the LH side.

  29. INSTALL TIE ROD END SUB-ASSEMBLY LH  . Refer to INSTALLATION - Step 5
  30. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as described for the LH side.

  31. INSTALL FRONT SPEED SENSOR LH  . Refer to INSTALLATION - Step 6
  32. INSTALL FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure as described for the LH side.

  33. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  . Refer to INSTALLATION - Step 7
  34. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure as described for the LH side.

  35. INSTALL FRONT AXLE SHAFT LH NUT  . Refer to INSTALLATION - Step 8
  36. INSTALL FRONT AXLE SHAFT RH NUT 

    HINT: 

    Use the same procedure as described for the LH side.

  37. INSTALL FRONT EXHAUST PIPE ASSEMBLY  . Refer to INSTALLATION - Step 4
  38. INSTALL FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET  . Refer to INSTALLATION - Step 6
  39. CONNECT STEERING GEAR OUTLET RETURN TUBE  . Refer to INSTALLATION - Step 52
  40. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE  . Refer to INSTALLATION - Step 53
  41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install the transmission control cable assembly to the control shaft lever with the nut.
      Fig 21: Locating No. 2 Shift Cable Grommet Retainer Nut
      GTY300695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    2. Connect the transmission control cable assembly with a new clip to the No. 1 transmission control cable bracket.
      Fig 22: Locating Transmission Cable Bracket Clip
      GTY306647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. CONNECT ENGINE WIRE  . Refer to INSTALLATION - Step 55
  43. INSTALL UPPER RELAY BLOCK COVER 
  44. INSTALL STARTER ASSEMBLY  . Refer to INSTALLATION - Step 1
  45. INSTALL ECM  . Refer to INSTALLATION - Step 1
  46. CONNECT HEATER WATER OUTLET HOSE A  . Refer to INSTALLATION - Step 59
  47. CONNECT HEATER WATER HOSE INLET A  . Refer to INSTALLATION - Step 60
  48. CONNECT NO. 1 OIL COOLER OUTLET HOSE  . Refer to INSTALLATION - Step 6
  49. CONNECT NO. 1 OIL COOLER INLET HOSE  . Refer to INSTALLATION - Step 7
  50. INSTALL RADIATOR HOSE OUTLET  . Refer to INSTALLATION - Step 63
  51. INSTALL RADIATOR HOSE INLET  . Refer to INSTALLATION - Step 64
  52. CONNECT FUEL TUBE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 65
  53. INSTALL INTAKE AIR SURGE TANK ASSEMBLY  . Refer to INSTALLATION - Step 3
  54. CONNECT NO. 1 FUEL VAPOR FEED HOSE  . Refer to INSTALLATION - Step 67
  55. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY  . Refer to INSTALLATION - Step 68
  56. INSTALL NO. 1 AIR CLEANER INLET  . Refer to INSTALLATION - Step 69
  57. INSTALL AIR CLEANER CASE  . Refer to INSTALLATION - Step 70
  58. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  . Refer to INSTALLATION - Step 4
  59. INSTALL NO. 2 AIR CLEANER INLET  . Refer to INSTALLATION - Step 72
  60. CONNECT VACUUM HOSES  . Refer to INSTALLATION - Step 73
  61. INSTALL ENGINE MOVING CONTROL ROD  . Refer to INSTALLATION - Step 74
  62. INSTALL NO. 2 ENGINE MOUNTING STAY RH  . Refer to INSTALLATION - Step 75
  63. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
  64. INSTALL V-RIBBED BELT  . Refer to INSTALLATION - Step 1
  65. INSTALL BATTERY 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

  66. INSTALL COWL TOP PANEL OUTER 
  67. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to INSTALLATION - Step 2
  68. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 1
  69. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  . Refer to INSTALLATION - Step 3
  70. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  . Refer to INSTALLATION - Step 4
  71. INSTALL FRONT WHEELS  . Refer to INSTALLATION - Step 84
  72. ADD ENGINE COOLANT  . Refer to REPLACEMENT - Step 2
  73. ADD POWER STEERING FLUID 
  74. BLEED POWER STEERING SYSTEM  . Refer to ON-VEHICLE INSPECTION - Step 2
  75. ADD AUTOMATIC TRANSAXLE FLUID 

    HINT: 

    Refer to ADJUSTMENT .

  76. INSPECT SHIFT LEVER POSITION  See step  1
  77. ADJUST SHIFT LEVER POSITION  See step  2
  78. INSPECT FOR ENGINE COOLANT LEAK  . Refer to REPLACEMENT - Step 3
  79. INSPECT FOR FUEL LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  80. INSPECT FOR EXHAUST GAS LEAK 
  81. INSPECT IGNITION TIMING  . Refer to ON-VEHICLE INSPECTION - Step 2
  82. INSPECT ENGINE IDLE SPEED  . Refer to ON-VEHICLE INSPECTION - Step 3
  83. CHECK FUNCTION OF THROTTLE BODY  . Refer to ON-VEHICLE INSPECTION - Step 1
  84. INSTALL V-BANK COVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 14
  85. INSTALL COOL AIR INTAKE DUCT SEAL  . Refer to INSTALLATION - Step 101
  86. INSPECT CO/HC  . Refer to ON-VEHICLE INSPECTION - Step 5
  87. INSPECT ABS SPEED SENSOR SIGNAL 

    HINT: 

    Refer to TEST MODE PROCEDURE .

  88. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    HINT: 

    Refer to ADJUSTMENT .

  89. INSTALL FRONT FENDER APRON SEAL RH 
  90. INSTALL ENGINE UNDER COVER LH 
  91. INSTALL ENGINE UNDER COVER RH 
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