check oil TOYOTA CAMRY V20 1986 Service Information

IN0036
Seal Lock Adhesive
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in order to facilitate
reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative cable four the battery terminal.
(b) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the cable from
the negative (-) terminal which is grounded to the
vehicle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight
up without twisting it or prying it.
(d) Clean the battery terminal posts and cable termi-
nals with a shop rag. Do not scrape them with a file
or other abrasive object.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer or such to tap the terminal onto
the post.
(f) Be sure the cover for the positive (+) terminals are
properly in place.
4. Check hoses and wiring connectors to make sure
that they are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, O-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the ºrº symbol.
6. Precoated parts
Precoated parts are the bolts and nuts, which have
been coated with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated
with the specified adhesive.
(b) Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut
or installation part threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
(c) Precoated parts are indicated in the component il-
lustrations by the º
º symbol.
IN-4- INTRODUCTIONGeneral Repair Instructions

Illustration
Part No. Part Name
Note
09031 - 00030
Pin Punch
Part Name
Note
Feeler gauge
Check major clearance.
Vernier caliper with depth gauge
Check length of second coast brake piston rod.
Dial indicator with magnetic base
Check piston stroke and end play of the output shaft.
Dial indicator Check inside diameter of major bushing.
Straight edge Check side clearance of oil pump.
Torque wrenchPart Name Part No. Use etc.
Seal packing 1281,
Three bond 1281 or equivalent08826 - 00090Transfer right case y Transfer left case (A540H)
Transfer inspection hole cover (A540H)
Transfer case y Differential carrier cover
Differential LH bearing retainer (A540E, A540H)
Differential RH retainer (A540E)
Transaxle y Transfer assembly (A540H)
Adhesive 1324,
Three bond 1324 or equivalent08833 - 00070Differential LH bearing retainer set bolt
Differential carrier cover set bolt
Torque converter mounting bolt
Differential RH retainer set bolt (A540E)
Transfer set bolt (A540H)
SSM (SPECIAL SERVICE MATERIALS)
RECOMMENDED TOOL
EQUIPMENT
AT-12- AUTOMATIC TRANSAXLEPreparation

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

COMPONENT PARTS
General Notes
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-looking parts of different subassemblies being on
your workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the
next component group. If a component group can not be assembled because parts are being or-
dered, be sure to keep all parts of that group in a separate container while proceeding with disas-
sembly, inspection, repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: A540E ATF DEXRON
II
A540H ATF Type T or equivalent
Recommended oil for the transfer: Transaxle oil E50, API GL5, SAE 75W-90 or equivalent
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean, with any fluid passages and holes blown
through with compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent acciden-
tally spraying automatic transaxle fluid or kerosene in your face.
3. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper order to allow efficient inspection,
repairs, and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corre-
sponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle
fluid for at least fifteen minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are
installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be re-
placed.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
- AUTOMATIC TRANSAXLEComponent Parts (General Notes)AT-39

AT2732
AT0153
AT0154
AT0155 AT3611
3. REMOVE STATOR SHAFT
Remove the eleven bolts and stator shaft.
HINT: Keep the gears in assembly order.
4. REMOVE FRONT OIL SEAL
Pry off the oil seal with a screwdriver.
INSPECTION OF OIL PUMP
1. CHECK BODY CLEARANCE OF DRIVEN GEAR
Push the driven gear to one side of the body.
Using a feeler gauge, measure the clearance.
Standard body clearance: 0.07 - 0.15 mm
(0.0028 - 0.0059 in.)
Maximum body clearance: 0.3 mm (0.012 in.)
If the body clearance is greater than the maximum, re-
place the oil pump body subassembly.
2. CHECK TIP CLEARANCE OF DRIVEN GEAR
Measure between the driven gear teeth and the cres-
cent-shaped part of the pump body.
Standard tip clearance: 0.11 - 0.14 mm
(0.0043 - 0.0055 in.)
Maximum tip clearance: 0.3 mm (0.012 in.)
If the tip clearance is greater than the maximum, replace
the oil pump body subassembly.
3. CHECK SIDE CLEARANCE OF BOTH GEARS
Using a steel straightedge and a feeler gauge, measure
the side clearance of both gears.
Standard side clearance: 0.002 - 0.005 mm
(0.0008 - 0.0020 in.)
Maximum side clearance: 0.1 mm (0.004 in.)
AT-44- AUTOMATIC TRANSAXLEComponent Parts (Oil Pump)

AT3612
AT0156
SST
AT0157AT7708
There are three different thicknesses for drive and driven
gears.
Drive and driven gear thickness
Mark Thickness
A 9.440 - 9.456 mm (0.3717 - 0.3723 in.)
B 9.456 - 9.474 mm (0.3723 - 0.3730 in.)
C 9.474 - 9.490 mm (0.3730 - 0.3736 in.)
If the thickest gear can not make the side clearance
within standard specification, replace the oil pump body
subassembly.
4. CHECK OIL PUMP BODY BUSHING
Using a dial indicator, measure the inside diameter of
the oil pump body bushing.
Maximum inside diameter: 38.18 mm (1.5031 in.)
If the inside diameter is greater than the maximum, re-
place the oil pump body subassembly.
5. CHECK STATOR SHAFT BUSHING
Using a dial indicator, measure the inside diameter stator
shaft bushing.
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the inside diameter is greater than the maximum, re-
place the stator shaft.
ASSEMBLY OF OIL PUMP
1. INSTALL FRONT OIL SEAL
Using SST and a hammer, install a new oil seal. The
seal end should be flush with the outer edge of the
pump body.
SST 09350-32014 (09351-32140)
2. INSTALL DRIVEN GEAR AND DRIVE GEAR
Make sure the top of the gears are facing upward.
- AUTOMATIC TRANSAXLEComponent Parts (Oil Pump)AT-45

AT3609
AT3610
AT0161 AT3611
3. INSTALL STATOR SHAFT TO PUMP BODY
(a) Align the stator shaft with each bolt hole.
(b) Torque the eleven bolts.
Torque: 100 kg-cm (7 ft-lb, 10 N-m)
4. INSTALL THRUST WASHER
(a) Coat the thrust washer with petroleum jelly.
(b) Align the tab of the washer with the hollow of the
pump body.
5. INSTALL OIL SEAL RINGS
Install the two oil seal rings to the stator shaft back
side.
NOTICE: Do not spread the ring ends more than nec-
essary.
HINT: After installing the oil seal rings, check that they
move smoothly.
6. CHECK PUMP DRIVE GEAR ROTATION
Turn the drive gear with two screwdrivers and make
sure it rotates smoothly.
NOTICE: Be careful not to damage the oil seal lip.
AT-46- AUTOMATIC TRANSAXLEComponent Parts (Oil Pump)

AT7709
SST
AT7710AT3613
r Non-reusable partPlateDiscFlangeSnap Ring Thrust Washer Clutch DrumPistonr O-RingSnap Ring Piston Return
Spring
Direct Clutch
COMPONENTS
DISASSEMBLY OF DIRECT CLUTCH
1. CHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Using a dial indicator (long type pick or SST),
measure the direct clutch piston stroke applying
and releasing the compressed air (4 - 8 kg/cm
2,
57 - 114 psi, 392 - 785 kPa) as shown.
SST 09350-32014 (09351-32190)
Piston stroke: A540E 0.91 - 1.35 mm
(0.0358 - 0.0531 in.)
A540H 1.11 - 1.47 mm
(0.0437 - 0.0579 in.)
If the piston stroke is greater than the maximum, inspect
each component.
- AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch)AT-47

AT7710 AT2733
SST
AT3617
Plate DiscFlange
AT0171
AT7709
SST
(b) Place SST on the spring retainer, and compress
the return spring with a shop press.
SST 09350-32014 (09351-32070)
(c) Install the snap ring using snap ring pliers. Be
sure the end gap of snap ring is not aligned with
the spring retainer claw.
3. INSTALL PLATES, DISCS AND FLANGE
(a) Install plates and discs.
Install in order: P = Plate D = Disc
P-D-P-D-P-D
(b) Install the flange with the flat end facing downward.
4. INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned
with one of the cutouts.
5. RECHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Using a dial indicator (long type pick or SST),
measure the direct clutch piston stroke applying
and releasing the compressed air (4 - 8 kg/cm
2,
57 - 114 psi, 392 - 785 kPa) as shown.
SST 09350-32014 (09351-32190)
Piston stroke: A540E 0.91 - 1.35 mm
(0.0358 - 0.0531 in.)
A540H 1.11 - 1.47 mm
(0.0437 - 0.0579 in.)
If the piston stroke is nonstandard, select another
flange.
HINT: There are two different thicknesses for the
flange.
Flange thickness: 2.70 mm (0.1063 in.)
3.00 mm (0.1181 in.)
AT-50- AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch)

AT3619
SST
AT3620
A540E
AT4342Plate r Non-reusable partFlangeSnap Ring DiscSpring
Retainer A540HSnap Ring Oil Seal
RingClutch Drum BearingPistonBearingr O-RingReturn
Spring
A540H
Forward Clutch
COMPONENTS
DISASSEMBLY OF FORWARD CLUTCH
1. CHECK PISTON STROKE OF FORWARD CLUTCH
Using a dial indicator (long type pick or SST), measure
the forward clutch piston stroke applying and releasing
the compressed air (4 - 8 kg/cm
2, 57 - 114 psi, 392 -
785 kPa) as shown.
SST 09350-32014 (09351-32190)
Piston stroke: 1.41 - 1.82 mm
(0.0555 - 0.0717 in.)
If the piston stroke is greater than the maximum, inspect
each component.
- AUTOMATIC TRANSAXLEComponent Parts (Forward Clutch)AT-51