transmission TOYOTA CAMRY V20 1986 Service Information

INSTALLATION OF 4±SPEED GEAR
UNIT
1. INSTALL PARKING LOCK PAWL
(a) Place the parking lock pawl onto the case.
Hook the spring ends to the case and pawl.
(b) Install the pin into the hole of the case through the
spring and pawl.
2. INSTALL MANUAL VALVE SHAFT
(a) Coat the oil seal lip with the MP grease.
(b) Install the manual valve shaft oil seal to the case.
(d) Install the manual valve shaft to the transmission
case through the manual valve lever.
(e) Install the parking lock rod.
(f) Using a pin punch, drive in the roll pin until its sur-
face is flush with the manual valve lever sur-
face. (c) Assemble a new collar to the manual valve lever.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±391

5. INSTALL FIRST AND REVERSE BRAKE PISTON TO
TRANSMISSION CASE
(a) Coat the new 4±rings with ATF.
(b) Install the two O±rings on the piston. 4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the
manual valve fever is in the P range. 3. INSTALL PARKING LOCK PAWL BRACKET
Torque: 75 kg±cm (65 in.±Ib, 7.4 N±m)
(g) Match the collar hole to the lever calking hollow
and calk the collar to the lever.
(h) Install the retaining spring.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±392

(b) Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the transmission
case.
NOTICE: Do not push on the oil pump strongly or the
oil seal ring will stick to the direct clutch drum.
(c) Install and tighten the seven bolts.
Torque:. 225 kg±cm (16 ft±Ib, 22 N±m)
26. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.
Thrust play: 0.13 ± 0.90 mm (0.0051 ± 0.0354 in.)
HINT: There are two different±thick bearings (A540E) or
races (A540H) for the end of stator shaft. If the thrust
play is in excess of standard, select one of them.
(A540E)
Bearing thickness: 3.60 mm (0.1417 in.)
4.19 mm (0.1650 in.)
(A540H)
Race thickness: 0.8 mm (0.031 in.)(e) Install the direct clutch and forward clutch into the
case.
HINT: Hold the direct clutch toward the forward
clutch to prevent the thrust washer from getting
out of place.
25. INSTALL OIL PUMP INTO CASE
(a) Coat a new O±ring with ATF and install it to the oil
purnp.(f) Check the distance between the direct clutch
drum and the sun gear input drum.
Distance: Approx. 3mm (0.12 in.)
0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±401

The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator,
water pump, thermostat, electric fan, hoses and other components.
Coolant which is heated in the water jacket is pumped to the radiator, through which an electric fan blows air
to cool the coolant as it passes through. Coolant which has been cooled is then sent back to the engine by
the water pump, where it cools the engine.
The water jacket is a network of channels in the shell of the cylinder block and cylinder head through which
coolant passes. It is designed to provide adequate cooling of the cylinders and combustion chambers which
become heated during engine operation.
RADIATOR
The radiator performs the function of cooling the coolant which has passed through the water jacket and be-
come hot, and it is mounted in the front of the vehicle. The radiator consists of an upper tank and lower tank,
and a core which connects the two tanks. The upper tank contains the inlet for coolant from the water jacket
and the filler inlet. It also has a hose attached through which excess coolant or steam can flow. The lower
tank has an outlet and drain cock for the coolant. The core contains many tubes through which coolant flows
from the upper tank to the lower tank as well as cooling fins which radiate heat away from the coolant in the
tubes.
The air sucked through the radiator by the electric fan, as well as the wind generated by the vehicle's travel,
passes through the radiator, cooling the coolant. Models with automatic transmission include an automatic
transmission fluid cooler built into the lower tank of the radiator. A fan with an electric motor is mounted be-
hind the radiator to assist the flow of air through the radiator. The fan operates when the coolant tempera-
ture becomes high in order to prevent it from becoming too high.
RADIATOR CAP
The radiator cap is a pressure type cap which seals the radiator, resulting in pressurization of the radiator as
the coolant expands. The pressurization prevents the coolant from boiling even when the coolant tempera-
ture exceeds 100°C (212°F). A relief valve (pressurization valve) and a vacuum valve (negative pressure
valve) are built into the radiator cap. The relief valve opens and lets steam escape through the overflow pipe
when the pressure generated inside the cooling system exceeds the limit (coolant temperature: 110 ±
120°C, 230 ± 248°F, pressure; 0.3 ±1.0 kg/cm
2, 4.3 ±14.2 psi, 29.4 ± 98.1 kPa). The vacuum valve opens to
alleviate the vacuum which develops in the coolant system after the engine is stopped and the coolant tem-
perature drops.
The valves's opening allows the coolant in the reservoir tank to return to the cooling system.
RESERVOIR TANK
The reservoir tank is used to catch coolant which overflows the cooling system as a result of volumetric ex-
pansion when the coolant is heated. The coolant in the reservoir rank returns to the radiator when the cool-
ant temperature drops, thus keeping the radiator full at all times and avoiding needless coolant loss. Check
the reservoir tank level to find out if the coolant needs to be replenished.
WATER PUMP
The water pump is used for forced circulation of coolant through the cooling system. It is mounted on the
front of the cylinder block and driven by a timing belt.
THERMOSTAT
The thermostat has a wax type by±pass valve and is mounted in the water inlet housing. The thermostat in-
cludes a type of automatic valve operated by fluctuations in the coolant temperature. This valve closes when
the coolant temperature drops, preventing the circulation of coolant through the engine and thus permitting
the engine to warm up rapidly. The valve opens when the coolant temperature has risen, allowing the cir-
culation of coolant. Wax inside the thermostat expands when heated and contracts when cooled. Heating
the wax thus generates pressure which overpowers the force of the spring which keeps±the valve closed,
thus opening the valve. When the wax cools, its contraction causes the force of the spring to take effect
once more, closing the valve. The thermostat in this engine operates at a temperature of 82°C (180°F).
± COOLING SYSTEMDescriptionCO±3

INSTALLATION OF RADIATOR
1. INSTALL ELECTRIC COOLING FANS TO RADIATOR
2. INSTALL RADIATOR
Place the radiator in position, and install the two supports
with the two bolts.
HINT: After installation, check that the rubber cushion (A)
of the supports are not depressed.
3. (A/T)
CONNECT OIL COOLER HOSES
4. CONNECT COOLING FAN MOTOR CONNECTORS
5. CONNECT RADIATOR HOSES
6. CONNECT COOLANT RESERVOIR HOSE
7. INSTALL IGNITION COIL (2VZ±FE), IGNITER AND
BRACKET ASSEMBLY
8. INSTALL BATTERY
Connect the grand strap.
9. FILL WITH ENGINE COOLANT (See page CO±5)
10. START ENGINE AND CHECK FOR LEAKS
11. (A/T)
CHECK AUTOMATIC TRANSMISSION (A/T) FLUID
LEVEL
NOTICE: Do not overfill.
(d) Check for water leaks.
HINT: On radiators with resin tanks, there is a clearance
between the core plate and tank plate where a minute
amount of air will remain, giving the appearance of an
air leak when the radiator is submerged in water. There-
fore, before performing the water leak test, first switch
the radiator around in the water until all air bubbles dis-
appear.
7. PAINT TANK PLATE
HINT: If the water leak test checks out okay, allow the radia-
tor to completely dry and then paint the tank plate.
± COOLING SYSTEMRadiatorCO±20

DIAGNOSIS SYSTEM
DESCRIPTION
The ECU contains a built±in, self±diagnosis system which de-
tects troubles within the engine signal network and then flashed
a
warning on the ºCHECKº engine warning light on the instrument
panel flashes.
By analyzing various signals shown in the tables (See pages FI±
25 or 27) the ECU detects system malfunctions which are re-
lated to the various operating parameter sensors or actuator.
The ECU
stores the failure code associated with the detected failure until
the diagnosis system is cleared by removing the EFI fuse with
the ignition switch OFF.
A ºCHECKº engine warning light on the instrument panel informs
the driver that a malfunction has been detected.
The light goes oft automatically when the malfunction has been
cleared.
OUTPUT OF DIAGNOSTIC CODES
To obtain an output of diagnostic codes, proceed as follow:
1. Initial conditions
(a) Battery voltage 11 V or more
(b) Throttle valve fully closed (throttle position sensor IDL
points closed)
(e) Transmission in neutral position
(d) Accessories switched OFF
(e) Engine at normal operating temperature
2. Turn the ignition switch to ON. Do not start the engine.
3. Using SST, connect terminals TE1 and E1 of the check con-
nector.
SST 09843±18020
ºCHECKº ENGINE WARNING LIGHT
CHECK
1. The ºCHECKº engine warning light will come on when the igni-
tion switch is placed at ON and the engine is not
running.
2. When the engine is started, the ºCHECKº engine warning light
should go off.
If the light remains on, the diagnosis system has detected a
malfunction or abnormality in the system.
± EFI SYSTEMDiagnosis SystemFI±22

2. INSPECT INJECTOR RESISTANCE
(a) Disconnect the injector connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Resistance: Approx. 13.8


If the resistance is not as specified, replace the injector.
(c) Reconnect the injector connector.
ON±VEHICLE INSPECTION
1. INSPECT INJECTOR OPERATION
Check operation sound from each injector.
(a) With the engine running or cranking, use a sound scope to
check that there is normal operating noise in proportion to
engine rpm.
(b) If you have no sound scope, you can check the injector
transmission operation with your finger.
If no sound or an unusual sound is heard, check the wiring
connector, injector or injection signal from ECU.
Injectors (3S±FE)
± EFI SYSTEMFuel System (Injectors (3S±FE))FI±88

2. INSPECT INJECTOR RESISTANCE
(a) Disconnect the injector connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Resistance: Approx. 13.8


If the resistance is not as specified, replace the injector.
(c) Reconnect the injector connector.
ON±VEHICLE INSPECTION
1. INSPECT INJECTOR OPERATION
Check operation sound from each injector.
(a) With the engine running or cranking, use a sound scope to
check that there is normal operating noise in proportion to
engine rpm.
(b) If you have no sound scope, you can check the injector
transmission operation with your finger.
If no sound or an unusual sound is heard, check the
wiring connector, injector or injection signal from ECU.
Injectors (2VZ±FE)
± EFI SYSTEMFuel System (Injectors (2VZ±FE))FI±93

(b) Using SST, connect terminals TE1 and E1 of the check
connector.
SST 09843±18020
(c) After engine rpm are kept at 1,000 ± 1,300 rpm for 5
seconds, check that they return to idle speed.
If the rpm operation is not as specified, check the ISC
valve, wiring and ECU.
(d) Remove the service wire.
2. INSPECT ISC VALVE RESISTANCE
(a) Disconnect the ISC valve connector.
(b) Using an ohmmeter, measure the resistance between termi-
nal +B and other terminals (ISC1, ISC2).
Resistance: 16.0 ± 17.0


If the resistance is not as specified, replace the ISC valve.
(c) Reconnect the ISC valve connector.
ON±VEHICLE INSPECTION
1. INSPECT ISC VALVE OPERATION
(a) Initial conditions:
wEngine at normal operating temperature
wIdle speed set correctly
wTransmission in ºNº range
Idle Speed Control (ISC) Valve
(3S±FE)
± EFI SYSTEMAir Induction System (Idle Speed Control (ISC) Valve (3S±FE)FI±116

ADJUSTMENT OF IGNITION TIMING
3S±FE (See steps 7 to 10 on pages IG±16 and 17)
2VZ±FE (See steps 6 to 11 on pages IG±20 and 21)
Ignition timing:
10°BTDC @ idle
(w/ Terminals TE1 and E1 connected)
ADJUSTMENT OF IDLE SPEED (3S±FE)
(See HINT on page FI±17)
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All vacuum lines connected
HINT: All vacuum hoses for EGR systems, etc. should be
properly connected.
(e) EFI system wiring connectors fully plugged
(f) All accessories switched OFF
(g) Transmission in N range
2. CONNECT TACHOMETER (See page IG±16)
3. ADJUST IDLE SPEED
(a) Using SST, connect terminals TE1 and E1 of the check
connector.
SST 09845±18020
HINT: Decrease the rpm after the engine maintains a speed
of the 1,000 ± 1,300 rpm for 5 seconds.
(d) Remove SST.
4. FURTHER CHECK IDLE SPEED
Idle speed: 700
+ 5O rpm
If the idle speed is not within these values, carry out either of
the below listed procedures and then recheck the idle speed.
Carry out a driving test, including stop±go several times at a
speed above 10 km/h, or± start the engine, idle for
30 seconds and then turn the engine 'off repeatedly. By
doing this, idle data will be stored in the ISC and the idle rpm
will be at specified value.(b) Check the idle speed.
Idle speed: 660 rpm or more
(c) If the idle speed is not as specified, adjust the idle speed
by turning the IDLE SPEED ADJUSTING
SCREW.
± ENGINE MECHANICALEngine Tune±UpEM±19