engine TOYOTA CAMRY V20 1986 Service Information

AT3754
Electronic Control
SystemDifferential Hydraulic Control
SystemTorque
ConverterLock-up
Clutch 4-speed Planetary
Gear Unit
Sectional View
DESCRIPTION
GENERAL
(A540E)
The A540E is a 4-speed, Electronic Controlled Transaxle (hereafter called ECT) developed exclusively
for use with a transversely-mounted engine. A lock-up is built into the torque converter.
The A540E transaxle is mainly composed of the torque converter, the 4-speed planetary gear unit, the
differential, the hydraulic control system and the electronic control system.
AT-2- AUTOMATIC TRANSAXLEDescription

AT5032
(A540H)
The A540H automatic transaxle design is based on the A540E automatic transaxle and equipped with a
center differential and transfer.
This transaxle has the same hydraulic multiplate clutch in the center differential limiting control mecha-
nism as the A241H automatic transaxle on the Corolla All-Trac/4WD Station Wagon. The fluid pressure
acting on the hydraulic multiplate clutch of the A540H is controlled by the ECT ECU (Electronic Control
Unit) according to the vehicle driving conditions. As a result, torque is distributed to the front and rear
wheels appropriately at all times to maximize the overall performance of the 4WD vehicle.
NOTICE: Special handling methods are necessary for full-time 4WD vehicles during inspection and
maintenance. Instructions concerning these handling methods are given on Camry Repair Manual
(Pub. No. RM199U) on page IN-8.
Hydraulic Multiplate ClutchTransfer Front DifferentialCenter
Differential 4-Speed Planetary Gear
Unit and Hydraulic
Control SystemNo. 1 and No. 2 Center Differential
Control Solenoid ValveCenter Differential ControlECT
ECU No. 1 and No. 2 Shift Control
Solenoid Valves and Lock-up
Control solenoid ValveEngine ECU
Throttle Position
Sensor
Stop Light Switch
Vehicle Speed
Sensors
Mode Select Switch
Neutral Start Switch
O/D Main Switch
Center Deff. Control
Switch Shift Control Sectional View
Sensors
- AUTOMATIC TRANSAXLEDescriptionAT-3

Type of Transmission
A540E
A540H
Type of Engine
2VZ-FE
3S-FE
Torque ConverterStall Torque Ratio
1.9 : 1
2.0 : 1
Lock-Up Mechanism
Equipped
u
Gear Ratio1st Gear
2.810
u
2nd Gear
1.549
u
3rd Gear
1.000
u
O/D Gear
0.734
u
Reverse Gear
2.296
Number of Discs and
Plates (Disc/Plate)C
0O/D Direct Clutch
2/2
u
C
1Forward Clutch 4/4
u
C
2Direct Clutch 3/3
u
B
22nd Brake
3/3
u
B
3First & Reverse Brake 7/7 6/6
B
0O/D Brake
3/3
u
mm (in.)B1 Band Width
38 (1.50)
25 (0.98)
AT FType
ATF DEXRON
IIATF Type T or
equivalent
Capacity liter
(US qts, Imp. qts)A/T5.9 (6.2, 5.2)
7.0 (7.4, 6.2)
D/F1.0 (1.1, 0.9)
Transfer OilTypeTransaxle oil E50,
API GL5,
SAE 75W-90
or equivalent
Capacity liter (US qts, Imp. qts)
0.7 (0.7, 0.6)
General Specification
u
AT-4- AUTOMATIC TRANSAXLEDescription

NOMENCLATURE
OPERATION
Forward Clutch
C
1Connects input shaft and front planetary ring gear
Direct Clutch
C
2Connects input shaft and front & rear planetary sun gear
2nd Coast Brake
B
1Prevents front & rear planetary sun gear from turning either clockwise or counterclockwise
2nd Brake
B
2Prevents outer race of F1 from turning either clockwise or counterclockwise, thus preventing front &
rear planetary sun gear from turning counterclockwise
1st & Reverse Brake
B
3Prevents rear planetary carrier from turning either clockwise or counterclockwise
No. 1 One-Way Clutch
F
1When B2 is operating, prevents front & rear planetary sun gear from turning counterclockwise
No. 2 One-Way Clutch
F
2Prevents rear planetary carrier from turning counterclockwise
O/D Direct Clutch
C
0Connects overdrive sun gear and overdrive-planetary carrier
O/D Brake
B
0Prevents overdrive sun gear from turning either clockwise or counterclockwise
O/D One-Way Clutch
B
0When transmission is being driven by engine, connects overdrive sun gear and overdrive carrier
Planetary GearsThese gears change the route through which driving force is transmitted in accordance with the
operation of each clutch and brake in order to increase or reduce the input and output speed
AT3207
Rear Planetary CarrierFront Planetary Ring Gear OUT O/D Planetary Sun GearINInput Shaft Shaft O/D Planetary CarrierIntermediateFront Planetary Carrier Rear Planetary
Ring Gear O/D Planetary Ring Gear
and Counter Drive Gear
FUNCTION OF COMPONENTS
Front and Rear Planetary Sun Gear
AT-6- AUTOMATIC TRANSAXLEOperation

AT1097
OUTIN
D or 2 Range 1st Gear
AT1102
OUTIN
2 Range 2nd Gear
AT1098
OUTIN
D Range 2nd Gear
AT1103
OUTIN
L Range 1st Gear
AT1099
OUTIN
D Range 3rd Gear
AT1101
OUTIN
R Range Reverse Gear
AT1100
OUTIN
D Range O/D Gear
Power from the engine transmitted to the input shaft via the torque converter is then transmitted to the
planetary gears by the operation of the clutch.
By operation of the brake and one-way clutch, either the planetary carrier or the planetary sun gear are
immobilized, altering the speed of revolution of the planetary gear unit.
Shift change is carried out by altering the combination of clutch and brake operation.
Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttle
opening angle and vehicle speed, and shift change automatically occurs.
The conditions of operation for each gear position are shown on the following illustrations:
- AUTOMATIC TRANSAXLEOperationAT-7

AT3543
SST
AT3544
Cover Piston
AT3545
AT3546
SST
AT3542
(b) Using SST, measure the piston stroke applying and
releasing the compressed air (4 - 8 kg/cm2
57 -
114 psi or 392 - 785 kPa) as shown.
SST 09240-00020
Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 in.)
If the piston stroke exceeds the limit, inspect the second
coast brake band (See page AT-41).
23. REMOVE SECOND COAST BRAKE PISTON
(a) Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)
(b) Remove the cover.
(c) Remove the piston and outer return spring.
(d) Remove the two O-rings from the cover.
24. STAND TRANSAXLE ENGINE SIDE UPWARD
25. REMOVE OIL PUMP
NOTICE: Before removing the oil pump, remove the
second coast brake piston.
(a) Remove the seven bolts.
(b) Using SST, pull out the oil pump from the transaxle
case.
SST 09350-32014 (09351-32061)
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-23

(e) Tighten the O±ring fittings or the bolted type fittings to
the specified torque.
4. WHEN CONNECTING MANIFOLD GAUGE;
(a) Be sure to connect the charging hose end with a pin
to the compressor charging valve.
(b) The letter ºDº engraved near the compressor service
valve indicates the high pressure side, and ºSº indi-
cates the low pressure side. Pay careful attention
when connecting the hose.
(c) Tighten hose by hand.
(d) To prevent loosening of connected hose, do not apply
drops of compressor oil to the seat of connection.
HINT: After connecting the manifold gauge and the refrig±
erant container (service can), discharge any air in the
hoses.
5. WHEN EVACUATING;
Approx. 15 minutes after removal, check the system for
leaks, then take at least another 15 minutes to make sure
the air is fully removed.
6. WHEN HANDLING REFRIGERANT CONTAINER
(SERVICE CAN);
(a) Must never be heated.
(b) Must be kept below 4

°C (1 04°F).
(c) If warming service can with hot water, be careful that
the valve on top of the service can is never immersed
in the water, as the water may permeate into the refrig-
erant cycle.
(d) Empty service cans must never be re±used.
7. WHEN A/C IS ON AND REFRIGERANT GAS IS
BEING REPLENISHED;
(a) If there is not enough refrigerant gas in the refrigerant
cycle, oil lubrication becomes insufficient and com-
pressor burnout may occur, so take care to avoid this.
(b) If the valve on the high pressure side is opened, refrig-
erant flows in reverse and causes the service can to
rupture, so only open and close the vlave on the low
pressure side.
(c) If the service can is inverted and refrigerant is inserted
in a liquid state, the liquid is compressed and the com-
pressor brakes down, so the refrigerant must be in-
serted in a g¿¿seous state.
(d) Be careful not to insert too much refrigerant gas, as
this causes trouble such as inadequate cooling, poor
fuel economy, engine overheat, etc.
8. WHEN USING GAS±CYLINDER TYPE LEAK
DETECTION INSTRUMENT;
(a) As a naked flame is used, first make sure that there are
no flammable substances nearby before using it.
(b) Be careful, as poisonous gas is produced when
refrigerant gas comes in contact with heat parts.
± AIR CONDITIONING SYSTEMGenera! InformationAC±3

AIR CONDITIONING SYSTEM CIRCUIT
(Lever Type on 3S±FE Engine FWD Model)
± AIR CONDITIONING SYSTEMAir Conditioning System CircuitAC±4

(Push Type on 3S±FE Engine FWD Model)
± AIR CONDITIONING SYSTEMAir Conditioning System CircuitAC±5

(Lever Type on 3S±FE Engine All±Trac/4WD Model)
± AIR CONDITIONING SYSTEMAir Conditioning System CircuitAC±6