TOYOTA CAMRY V20 1986 Service Information

MarkClassMarkClass
Hexagon
head bolt
4
Bolt
head No.4-
5-
6-
7-
8-
9-
10-
11 -4T
5T
6T
7T
8T
9T
10T
11 TStud bolt
No mark
4T
No mark4T
Grooved
6T Hexagon
flange bolt
w/ washer
hexagon boltNo mark4T
Hexagon
head bolt
Two
protruding
lines5T
Hexagon
flange bolt
w/ washer
hexagon boltTwo
protruding
lines6TWelded bolt
4T Hexagon
head bolt
Three
protruding
lines7T
Hexagon
head bolt
Four
protruding
lines8T
STANDARD BOLT TORQUE SPECIFICATIONS
HOW TO DETERMINE BOLT STRENGTH
B-2STANDARD BOLT TORQUE SPECIFICATIONS

ClassDiameter
mmPitch
mmSpecified torque
Hexagon head boltHexagon flange bolt
kg-cmft-lbN-m kg-cm ft-lbN-m
4T6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 5 48 in.-Ib
9
19
35
55
83 55
130
260
480
760
1,15052 in.-Ib
10
21
39
61
- 60
145
290
540
850
-6
14
29
53
84
-
5T6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
140 65
160
330
600
930
1,40056 in.-Ib
12
24
43
67
10175
175
360
670
1,050
-65 in.-lb
13
26
48
76
-7.5
17.5
36
65
100
-
6T6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
170 69 in.-lb
14
29
53
80
127 80
195
400
730
1,100
1,75090
210
440
810
1,250
-78 in.-lb
15
32
59
90
-9
21
44
80
125
-
7T6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.511 0
260
530
970
1,500
2,30010.5
25
52
95
145
230 8
19
38
70
108
16612
28
58
105
165
- 120
290
590
1,050
1,700
-9
21
43
76
123
-
8T8
10
121.25
1.25
1.2522
45
8029
61
11 0 300
620
1,10024
50
9033
68
120 330
690
1,250
9T8
10
121.25
1.25
1.2534
70
125 25
51
94 340
710
1,30027
57
105 380
790
1,45037
78
140
10T8
10
121.25
1.25
1.25390
800
1,45038
78
140 28
58
10531
64
11 6 430
890
1,60042
88
155
11 T8
10
121.25
1.25
1.2531
64
11 6 430
890
1,60042
87
155480
990
1,80047
97
175 35
72
130
SPECIFIED TORQUE FOR STANDARD BOLTS
STANDARD BOLT TORQUE SPECIFICATIONSB-3

Second
coast brakePiston stroke
Piston rod length2.0 - 3.5 mm
95.2 mm
96.3 mm0.079 - 0.138 in.
3.748 in.
3.791 in.
Oil pump
STD
Maximum
STD
Maximum
STD
Maximum
Maximum
Maximum
Maximum Body clearance
Tip clearance
Side clearance
Pump body bushing inside diameter
Stator shaft bushing inside diameter
Front side
Rear side0.07 - 0.15 mm
0.3 mm
0.11 - 0.14 mm
0.3 mm
0.02 - 0.05 mm
0.1 mm
38.18 mm
21.57 mm
27.07 mm0.0028 - 0.0059 in.
0.012 in.
0.0043 - 0.0055 in.
0.012 in.
0.0008 - 0.0020 in.
0.004 in.
1.5031 in.
0.8492 in.
1.0657 in.
Direct clutch
Maximum Piston stroke
Drum bushing inside diameter
Flange thickness0.0358 - 0.0531 in.
1.9004 in.
0.1063 in.
0.1181 in. 0.91 - 1.35 mm
48.27 mm
2.70 mm
3.00 mm
Forward
clutchPiston stroke
Flange thickness1.41 - 1.82 mm
3.00 mm
3.37 mm0.0555 - 0.0717 in.
0.1181 in.
0.1327 in.
Front
planetary
gearMaximum
Maximum
STD
Maximum Sun gear bushing inside diameter
Ring gear flange bushing inside diameter
Planetary pinion gear thrust clearance22.59 mm
30.08 mm
0.16 - 0.56 mm
0.61 mm0.8894 in.
1.1842 in.
0.0063 - 0.0220 in.
0.024 in.
Rear
planetary
gearPlanetary pinion gear thrust clearance
STD
Maximum0.16 - 0.56 mm
0.61 mm0.0063 - 0.0220 in.
0.024 in.
First and
reverse brakePack clearance0.85 - 2.05 mm0.033 - 0.081 in.
Overdrive
unitDirect clutch piston stroke
Direct clutch bushing inside diameter
Counter drive gear preload
Planetary pinion gear thrust clearanceMaximum
at Starting
STD
Maximum0.0689 - 0.0980 in.
0.8713 in.
940 - 1,560 g 2.1 - 3.4 lb 9.2 - 15.3 N1.75 - 2.49 mm
22.13 mm
0.0063 - 0.0220 in.
0.024 in. 0.16 - 0.56 mm
0.61 mm
AUTOMATIC TRANSAXLE (A540E)
Specifications
A-2- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

Valve body
spring
SpringFree length
mm (in.)Coil outer
diameter
mm (in.)Total
No. of
coilsColor
(Upper valve body)
Second coast modulator valve
B
1 orifice control valve
Down-shift plug
Throttle valve
Throttle modulator valve
Cut-back valve
No. 1 accumulator control valve
Lock-up relay valve27.5 (1.083)
24.8 (0.976)
29.8 (1.173)
30.7 (1.209)
21.7 (0.854)
21.8 (0.858)
28.1 (1.106)
26.6 (1.047)8.9 (0.350)
8.0 (0.315)
8.7 (0.343)
9.2 (0.362)
9.5 (0.374)
6.0 (0.236)
10.6 (0.417)
10.2 (0.402)14.6
12.0
13.5
9.5
9.5
13.5
13.0
11.5Brown
White
Yellow
Purple
Orange
Red
Yellow
Green
(Lower valve body)
Pressure relief valve
Check valve
Secondary regulator valve
No. 2 accumulator control valve
Second lock valve
3 - 4 shift valve
Low coast modulator valve
1 - 2 shift valve
2 - 3 shift valve
Primary regulator valve11.2 (0.441)
19.9 (0.783)
38.5 (1.516)
23.0 (0.906)
20.7 (0.815)
29.2 (1.150)
20.2 (0.795)
29.2 (1.150)
28.0 (1.102)
64.2 (2.528)6.4 (0.252)
11.0 (0.433)
8.4 (0.331)
6.3 (0.248)
6.1 (0.240)
8.9 (0.350)
7.9 (0.311)
8.9 (0.350)
9.4 (0.370)
18.6 (0.732)7.5
8.5
17.0
12.0
12.0
12.0
11.9
12.0
10.3
12.5None
None
Purple
Gray
Orange
Light green
Purple
Light green
None
None
Valve body
retainerRetainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
(Upper valve body)
Lock-up relay valve
Throttle modulator valve
Second coast modulator valve
Cut-back valve
No. 1 accumulator control valve
B
1 orifice control valve6.5 (0.256)
6.5 (0.256)
6.5 (0.256)
9.2 (0.362)
6.5 (0.256)
11.5 (0.453)5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
(Lower valve body)
Primary regulator valve
Secondary regulator valve
No. 2 accumulator control valve
Second lock valve
Low coast modulator valve
1 - 2 shift valve
2 - 3 shift valve
3 - 4 shift valve9.2 (0.362)
15.0 (0.591)
9.2 (0.362)
11.5 (0.453)
11.5 (0.453)
6.5 (0.256)
9.2 (0.362)
6.5 (0.256)5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
Specifications (Cont'd)
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-3

Accumulator
spring
SpringFree length
mm (in.)Coil outer
diameter
mm (in.)Total
No. of
coilsColor
Inner
Outer C
143.4 (1.709)
71.2 (2.803)17.8 (0.701)
24.4 (0.961)9.0
11.5Light Green
Blue
C
251.0 (2.008)
18.0 (0.709)
10.2
Red
C
0
(O/D case)Inner
Outer47.5 (1.870)
59.3 (2.335)18.9 (0.744)
25.5 (1.004)9.5
9.5White
Gray
B
258.5 (2.303)
15.2 (0.598)
15.9
Orange
B
0 (Valve body)
62.2 (2.449)
14.8 (0.583)
17.0
None
Differential
Side bearing adjusting shim thickness Drive pinion preload (at starting)
New Bearing
Reused bearing
Total preload (at starting)
New bearing
Reused bearing
Pinion to side gear backlash
Side gear thrust washer thickness
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H0.0787 in.
0.0807 in.
0.0827 in.
0.0846 in.
0.0866 in.
0.0886 in.
0.0906 in.
0.0925 in.
0.0945 in.
0.0965 in.
0.0984 in.
0.1004 in.
0.1024 in.
0.1043 in.
0.1063 in.
0.1083 in.
0.1103 in.
0.1122 in. 2.00 mm
2.05 mm
2.10 mm
2.15 mm
2.20 mm
2.25 mm
2.30 mm
2.35 mm
2.40 mm
2.45 mm
2.50 mm
2.55 mm
2.60 mm
2.65 mm
2.70 mm
2.75 mm
2.80 mm
2.85 mm 10 - 16 kg-cm 8.7 - 13.9 in.-lb 1.0 - 1.6 N-m
5 - 8 kg-cm 4.3 - 6.9 in.-lb 0.5 - 0.8 N-m
Add drive pinion preload
2.8 - 4.4 kg-cm 2.4 - 3.8 in.-lb 0.3 - 0.4 N-m
1.4 - 2.2 kg-cm 1.2 - 1.9 in.-lb 0.1 - 0.2 N -
0.05 - 0.20 mm 0.0020 - 0.0079 in.
0.80 mm 0.0315 in.
0.90 mm 0.0354 in.
1.00 mm 0.0394 in.
1.10 mm 0.0433 in.
1.20 mm 0.0472 in.
1.30 mm 0.0512 in.
1.40 mm 0.0551 in.
Specifications (Cont'd)
A-4- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

Second
coast brakeSame the A540E automatic transaxle (See page A-2)
Oil pump=
Direct clutch Piston stroke
Drum bushing inside diameter Maximum
Flange thickness1.11 - 1.47 mm
48.27 mm
2.70 mm
3.00 mm0.0437 - 0.0579 in.
1.9004 in.
0.1063 in.
0.1181 in.
Forward
clutchSame the A540E automatic transaxle (See page A-2)
Front
planetary gear=
Rear
planetary gear=
First and
reverse brakePack clearance 0.0409 - 0.0850 in.1.04 - 2.16 mm
Over drive
unitSame the A540E automatic transaxle (See page A-2)
Valve body
springSame the A540E automatic transaxle (See page A-3)
Valve body
retainerSame the A540E automatic transaxle (See page A-3)
Accumulator
springSame the A540E automatic transaxle (See page A-4) Part tightenedkg-cmft-lbN-m
Oil cooler pipe union
Oil pan
Valve body y Transaxle case
Accumulator y Cover
Oil pump y Transaxle case
O/D case y Transaxle case
Differential LH side bearing retainer
Differential RH retainer
Differential carrier cover
Oil pump body y Stator shaft
Upper valve body y Lower valve body
Differential left case y Right case
Ring gear y Differential case275
50
11 0
100
225
250
195
195
400
100
67
640
1,26027
4.9
11
10
22
25
19
19
39
10
6.6
63
124 20
43 in.-lb
8
7
16
18
14
14
29
7
58 in.-lb
46
91
Torque Specifications
AUTOMATIC TRANSAXLE (A540H)
Specifications
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-5

TransferDriven pinion preload (at starting)
Total preload (at starting)
Ring gear backlash
Driven pinion bearing cage
Driven pinion preload (at starting)
New bearing
Reused bearing
Center differential side gear backlash0.9 - 1.4 kg 2.0 - 3.1 lb 8.8 - 13.7 N
0.5 - 0.9 kg 1.1 - 2.0 lb 4.9 - 8.8 N
0.13 - 0.18 mm 0.0051 - 0.0071 in.
1.8 - 2.9 kg 4.0 - 6.4 lb 18 - 28 N
0.9 - 1.4 kg 2.0 - 3.1 lb 9 - 13 N
0.05 - 0.20 mm 0.0020 - 0.0079 DifferentialDrive pinion preload (at staring)
New bearing
Reused bearing
Total preload (at starting)
New bearing
Reused bearing
Pinion to side gear backlash
Side gear thrust washer thickness
Mark
A
B
C
D
E
F
G
Side bearing adjusting shim thickness
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
Differential end play2.00 mm
2.05 mm
2.10 mm
2.15 mm
2.20 mm
2.25 mm
2.30 mm
2.35 mm
2.40 mm
2.45 mm
2.50 mm
2.55 mm
2.60 mm
2.65 mm
2.70 mm
2.75 mm
2.80 mm
2.85 mm
0.18 - 0.82 mm0.0787 in.
0.0807 in.
0.0827 in.
0.0846 in.
0.0866 in.
0.0886 in.
0.0906 in.
0.0925 in.
0.0945 in.
0.0965 in.
0.0984 in.
0.1004 in.
0.1024 in.
0.1043 in.
0.1063 in.
0.1083 in.
0.1103 in.
0.1122 in.
0.0071 - 0.0323 in. 0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in. 1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm 10 - 16 kg-cm 8.7 - 13.9 in.-lb 1.0 - 1.6 N-m
5 - 8 kg-cm 4.3 - 6.9 in.-lb 0.5 - 0.8 N-m
2.3 - 3.7 kg-cm 2.0 - 3.2 in.-lb 0.2 - 0.4 N-m
1.2 - 1.9 kg-cm 1.0 - 1.6 in.-lb 0.1 - 0.2 N-m
0.05 - 0.20 mm 0.0020 - 0.0079 in.
Specifications (Cont'd)
TRANSFER (A540H)
Specifications
A-6- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

Transfer
(Cont'd)Center differential left side gear
thrust washer thickness
Center differential side gear
thrust clearance
Center differential right side gear
thrust washer thickness 0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0071 - 0.0248 in.
0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0571 in.
0.0591 in. 1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
0.18 - 0.63 mm
1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
1.45 mm
1.50 mm
Transfer lower valve body springFree length
mm (in.)Coil outer
diameter
mm (in.)Total
No. of
coilsColor
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve32.2 (1.272)
28.9 (1.138)
28.9 (1.138)7.6 (0.299)
7.0 (0.276)
7.0 (0.276)16
14
14None
None
None
Transfer lower valve body retainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve6.5 (0.256)
=
=5.0 (0.197)
=
=3.2 (0.126)
=
=
Center differential plate washer
2.13 mm
2.16 mm
2.19 mm
2.22 mm
2.25 mm
2.28 mm
2.31 mm
2.34 mm
2.37 mm
2.40 mm0.0839 in.
0.0850 in.
0.0862 in.
0.0874 in.
0.0886 in.
0.0898 in.
0.0909 in.
0.0921 in.
0.0933 in.
0.0945 in.
Specifications (Cont'd)
Mark
A
B
C
D
E
F
G
H
J
Mark
A
B
C
D
E
F
G
H
J
K
L
Mark
71
72
73
74
75
76
77
78
79
80
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-7

Part tightenedkg-cmft-lb N-m
Oil cooler pipe union and elbow
Oil pan
Valve body y Transaxle case
Accumulator y Cover
Oil pump y Transaxle case
O/D case y Transaxle case
Differential LH side bearing retainer
Differential carrier cover
Oil pump body y Stator shaft
Upper valve body y Lower valve body
Front differential right case y Front differential left case
Ring gear y Ring gear mounting case
Transfer right case retainer y Transfer right case
Transfer right case y Adjusting nut lock plate lock bolt
Transfer right case y Transfer left case
Transfer right case y Mode select lever and rod275
50
11 0
100
225
250
195
400
100
67
340
1,260
300
73
450
55
11 520
43 in.-lb
8
7
16
18
14
29
7
58 in.-lb
25
91
22
63 in.-lb
33
48 in.-lb
827
4.9
11
10
22
25
19
39
10
6.6
33
124
29
7.2
44
5.4
11 Transfer
(Cont'd)81
82
83
84
85
86
87
88
89
90
91
92
93
94
Mark
A
B
C
D
E
F
G
H
J
K Ring gear adjusting shim2.43 mm
2.46 mm
2.49 mm
2.52 mm
2.55 mm
2.58 mm
2.61 mm
2.64 mm
2.67 mm
2.70 mm
2.73 mm
2.76 mm
2.79 mm
2.82 mm
0.30 mm
0.33 mm
0.36 mm
0.39 mm
0.42 mm
0.45 mm
0.48 mm
0.51 mm
0.54 mm
0.57 mm0.0957 in.
0.0969 in.
0.0980 in.
0.0992 in.
0.1004 in.
0.1016 in.
0.1028 in.
0.1039 in.
0.1051 in.
0.1063 in.
0.1075 in.
0.1087 in.
0.1098 in.
0.1110 in.
0.0118 in.
0.0130 in.
0.0142 in.
0.0154 in.
0.0165 in.
0.0177 in.
0.0189 in.
0.0201 in.
0.0213 in.
0.0224 in.
Specifications (Cont'd)
Torque Specifications
A-8- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

ItemCapacity
Classification
Liters US qts
Imp. qts
Automatic
transaxle fluid
(w/o Differential
oil)A540E
Dry fill
Drain and refill5.9
2.56.2
2.65.2
2.2ATF DEXRON
II
A54H
Dry fill
Drain and refill7.0
3.37.4
3.56.2
2.9ATF type T (08886 - 00405) or equivalent
Differential oil
(w/ Automatic transaxle)
SV21 series
VZV21 series1.6
1.01.7
1.11.4
0.9ATF DEXRON
II
Transfer oil (A540H)
0.7
0.74 0.62
Recommended oil
Oil grade: API GL-5
Viscosity: SAE 75W-90 or 80W-90
SAE 90W
[above -18°C (0°F)]
SAE 80W
[below -18°C (0°F)]
Transaxle oil E50 (08885 - 80206) or
equivalent
Part tightenedkg-cm ft-lbN-m
Transfer right case y Oil strainer
Transfer left case y Rear wheel speed sensor
Transfer left case y Transfer inspection hole cover
Transfer left case y Drain plug
Transfer left case y Driven pinion bearing cage
Driven pinion bearing cage y Transfer extension housing
Transfer extension housing y Dynamic damper
Transfer right case y Oil pump cover
Transfer ring gear y Ring gear mounting case
Center differential control solenoid y Transfer valve body
Transfer valve body y Transfer left case
Neutral start switch bolt
Neutral start switch nut
Transfer assembly y Transaxle case48 in.-lb
48 in.-lb
12
29
29
19
19
69 in.-lb
71
10
8
48 in.-lb
61 in.-lb
51 55
55
160
400
400
260
260
80
985
145
11 0
55
70
7005.4
5.4
16
39
39
25
25
7.8
97
14
11
5.4
6.9
69
Torque Specifications (Cont'd)
LUBRICANT
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-9