Get AUTOMATIC TRANSAXLE (U240E) -> Automatic Transaxle Unit Guide for Toyota Avensis 4 Door First Generation (1997-2003)

AX–33

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

AX064–02

COMPONENTS

Battery

Air Cleaner Assembly

RH Drive Shaft

87 (890, 64)

64 (650, 47)

Torque Converter Clutch

18 (185, 13)

41 (420, 30)

Ground Cable

46 (470, 34)

x 6

52 (530, 38)

87 (890, 64)

Hole Plug

64 (650, 47)

z Snap Ring

LH Drive Shaft

225 (2,305, 167)

Control Cable

z Cotter Pin

Starter

Clip

Plug for Hydraulic Test

39 (400, 29)

10 (100, 7)

Lock Nut Cap

12 (120, 9)

39 (400, 29)

Exhaust Front Pipe

127 (1,300, 94)

Engine Under Cover RH

43 (440, 32)

Suction Hose (RHD)

Front Center Member

73 (740, 54)

Grommet

Engine Under Cover LH

x 5

62 (630, 46)

72 (740, 53)

z

Grommet

73 (740, 54)

Front Center Member

Protector

x 5

N·m (kgf·cm, ft·lbf) : Specified torque

39 (400, 29)

D09909

z Non–reusable part

AVENSIS/CORONA SUP (RM781E)

AX–34

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

AX111–01

REMOVAL

1.

2.

REMOVE BATTERY

REMOVE AIR CLEANER ASSEMBLY

3.

REMOVE STARTER

(a) Remove the nut and disconnect the connector.

(b) Remove the 2 bolts, bracket and starter.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

4.

DISCONNECT GROUND CABLE

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

D09912

D09913

D02517

D02518

5.

REMOVE 4 UPPER SIDE TRANSAXLE MOUNTING

BOLTS

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

6.

7.

INSTALL ENGINE SUPPORT FIXTURE

REMOVE ENGINE UNDER COVERS

8.

REMOVE LH SIDE ENGINE MOUNTING

A

Remove the 5 bolts, nut and LH engine mounting.

Torque:

A

A: 52 N·m (530 kgf·cm, 38 ft·lbf)

B: 87 N·m (890 kgf·cm, 64 ft·lbf)

REMOVE LH AND RH DRIVE SHAFTS (See page

SA–3)

9.

B

A

AVENSIS/CORONA SUP (RM781E)

AX–35

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

10. DISCONNECT SHIFT CONTROL CABLE

Remove the nut, clip and disconnect the shift control cable.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

11. DISCONNECT NEUTRAL START SWITCH CONNEC-

TOR AND SOLENOID CONNECTOR

12. DISCONNECT VEHICLE SPEED SENSOR CONNEC-

TOR

D09914

13. REMOVE EXHAUST FRONT PIPE

(a) Disconnect the oxygen sensor connector.

(b) Remove the 2 nuts from the exhaust manifold.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)

HINT:

At the time of installation, please refer to the following item.

Replace the used nuts with new ones.

(c) Remove the 2 bolts, nuts and exhaust front pipe with 2

gaskets.

D09915

Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)

HINT:

At the time of installation, please refer to the following item.

Replace the used nuts with new ones.

(d) Remove the 2 gaskets from the exhaust front pipe.

HINT:

At the time of installation, please refer to the following item.

Replace the used gaskets with new ones.

14. REMOVE FRONT CENTER MEMBER

(a) RHD:

A

C

Remove the nut and disconnect the suction hose from the

front center member.

(b) Remove the 9 bolts, 3 grommets, front center member

protector and front center member.

Torque:

A

A: 73 N·m (740 kgf·cm, 54 ft·lbf)

B: 39 N·m (400 kgf·cm, 29 ft·lbf)

C: 72 N·m (740 kgf·cm, 53 ft·lbf)

15. DISCONNECT OIL COOLER HOSES

B

D02064

D02523

AVENSIS/CORONA SUP (RM781E)

AX–36

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

16. SUPPORT TRANSAXLE

D02524

D10022

D02044

D10023

17. REMOVE ENGINE REAR MOUNTING BOLT

Torque: 87 N·m (890 kgf·cm, 64 ft·lbf)

18. REMOVE ENGINE REAR MOUNTING BRACKET

Remove the 3 bolts and engine rear mounting bracket.

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

19. REMOVE TRANSAXLE

(a) Turn the crankshaft to gain access and remove the 6 bolts

with holding the crankshaft pulley bolt by a wrench.

Torque: 41 N·m (420 kgf·cm, 30 ft·lbf)

HINT:

At the time of installation, please refer to the following item.

First, install the gray bolt. Then install 5 black bolts.

(b) Remove the 4 bolts.

Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)

(c) Lower the left side of the engine and remove the transaxle

from the engine.

HINT:

At the time of installation, please refer to the following item.

Temporarily tighten the transaxle mounting bolts.

AVENSIS/CORONA SUP (RM781E)

AX–37

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

AX066–02

INSTALLATION

1.

CHECK TORQUE CONVERTER INSTALLATION

Using a scale and a straight edge, measure the distance from

the installation surface to the front surface of the transaxle

housing.

Correct distance: More than 12.75 mm (0.502 in.)

2.

TRANSAXLE INSTALLATION

Installation is in the reverse order of removal (See page

AX–34).

D02529

HINT:

S

After installation, adjust the shift control cable and neutral

start switch (See page DI–62).

S

Fill ATF and check fluid level (See page DI–62).

Perform the test drive of the vehicle (See page DI–62).

AVENSIS/CORONA SUP (RM781E)

AUTOMATIC TRANSAXLE (U240E) -> Automatic Transaxle Unit for Your Toyota Avensis 4 Door First Generation (1997-2003)

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