service TOYOTA CAMRY V20 1986 Service Information

7. When necessary, use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tighten-
ing torques. Always use a torque wrench.
9. Use of special service tools (SST) and special ser-
vice materials (SSM) may be required, depending on
the nature of the repair. Be sure to use SST and SSM
where specified and follow the proper work proce-
dure. A list of SST and SSM can be found at the back
of this manual.
10. When replacing fuses, be sure the new fuse has the
correct amperage rating. DO NOT exceed the fuse
amp rating or use one of a lower rating.
11. Care must be taken when jacking up and supporting
the vehicle. Be sure to lift and support the vehicle at
the proper locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any
work on the vehicle raised on jack alone, even for a
small job that can be finished quickly.
- INTRODUCTIONGeneral Repair InstructionsIN-5

ABBREVIATIONS USED IN THIS MANUAL
A/T ATM Automatic Transmission
ATF Automatic Transmission Fluid
B
0 Overdrive Brake
B
1 Second Coast Brake
B
2 Second Brake
B
3 First and Reverse Brake
C
0 Overdrive Clutch
C
1 Forward Clutch
C
2 Direct Clutch
D Disc
D/F Differential
LH Left
MP Multipurpose
O/D Overdrive
P Plate
RH Right
SSM Special Service Materials
SST Special Service Tools
IN-6- INTRODUCTIONAbbreviations Used in This Manual

Illustration
09226 - 10010Part No.
Crankshaft Front &
Rear Bearing ReplacerPart Name
A540HNote
09240 - 00020
Wire Gauge Set
09308 - 00010Oil Seal PullerA540H
09316 - 12010Transfer Bearing
ReplacerA540H
09316 - 20011Transfer Bearing
Replacer
09316 - 60010Transmission &
Transfer Bearing
Replacer
(09316 - 00010)
(Replacer Pipe)
(09316 - 00040)
(Replacer ºCº)A540H
(09316 - 00060)
(Replacer ºEº)A540H
09318 - 12010Transfer Bearing
Adjusting Nut WrenchA540H
09325 - 12010Transmission Oil
PlugA540H
09325 - 20010Transmission Oil
PlugA540H
09326 - 20011Output Shaft Bearing
Lock Nut WrenchA540H
09330 - 00021Companion Flange
Holding ToolA540H
09350 - 32014TOYOTA Automatic
Transmission Tool
Set
PREPARATION
SST (SPECIAL SERVICE TOOLS)
- AUTOMATIC TRANSAXLEPreparationAT-9

Illustration
Part No.
Part Name
Note
(09308 - 10010)
(Oil Seal Puller)
(09351 - 32032)Counter Driven Gear
Holding Tool
(09351 - 32040)No. 1 Piston Spring
Compressor
(09351 - 32050)
(Snap Ring Expander)
(09351 - 32061)
(Oil Pump Puller)
(09351 - 32070)No. 2 Piston Spring
Compressor
(09351 - 32080)
(Lock Nut Wrench)
(09351 - 32090)Oil Seal Remover
& ReplacerA540H
(09351 - 32100)Drive Pinion Bearing
Replacer
(09351 - 32111)Side Bearing Race
ReplacerA540H
(09351 - 32120)Overdrive Bearing
Replacer
(09351 - 32140)
(Oil Seal Replacer)
(09351 - 32150)
(Oil Seal Replacer)
(09351 - 32190)
(Measure Terminal)
(09351 - 32200)No. 3 Piston Spring
Compressor
SST (SPECIAL SERVICE TOOLS) (Cont'd)
AT-10- AUTOMATIC TRANSAXLEPreparation

IllustrationPart No.Part NameNote
09502 - 12010Differential Bearing
ReplacerA540H
09506 - 35010Differential Drive
Pinion Rear Bearing
ReplacerA540H
09520 - 32012Differential Side Gear
Shaft PullerA540H
09608 - 30022Front Hub Bearing
Replacer SetA540H
(09550 - 00050)
(Replacer)A540H
(09608 - 05010)
(Handle)A540H
09608 - 32010Steering Knuckle
Oil Seal ReplacerA540H
09608 - 35014Axle Hub & Drive
Pinion Bearing
Tool SetA540H
(09608 - 06020)
(Handle)A540H
(09608 - 06120)Front Hub Outer
Bearing Cup ReplacerA540H
09612 - 65014Steering Worm
Bearing PullerRemove pinion shaft Bearing outer race
09950 - 00020
Bearing RemoverA540H
09950 - 00030Bearing Remover
AttachmentA540H
09950 - 20017
Universal Puller
SST (SPECIAL SERVICE TOOLS) (Cont'd)
- AUTOMATIC TRANSAXLEPreparationAT-1 1

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

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