1986 TOYOTA CAMRY V20 gas type

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

AT3529
AT3530
A540E
AT5636
Speed SensorA540H
AT3531
AT0103
6. REMOVE THROTTLE CABLE RETAINING BOLT AND
PLATE
7. REMOVE SOLENOID WIRE RETAINING BOLT
8. (A540E)
REMOVE NO. 2 SPEED SENSOR
(a) Disconnect the connector.
(b) Remove the bolt and pull out the speed sensor.
(c) Remove the O-ring from speed sensor.
9. (A540H)
REMOVE VEHICLE SPEED SENSOR
(a) Remove the bolt and pull out the speed sensor.
(b) Remove the O-ring from speed sensor.
10. REMOVE OIL PAN AND GASKET
(a) Remove the seventeen bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE: Do not turn the transaxle over as this will
contaminate the valve body with the foreign materials
in the bottom of the oil pan.
(c) Place the transaxle on wooden blocks to prevent
damage to the oil tube bracket.
11. EXAMINE PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Look carefully at the chips and particles in the oil pan
and on the magnet to anticipate what type of wear you
will find in the transaxle.
Steel (magnetic)... bearing, gear and plate wear
Brass (non-magnetic)... bushing wear
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-19

INSTALLATION OF COMPONENT PARTS
Disassembly, inspection and assembly of each component group have been indicated in the pre-
ceding chapter. Before assembly, make sure, again, that all component groups are assembled
correctly.
If something wrong is found in a certain component group during assembly, inspect and repair
this group immediately.
Recommended ATF: DEXRON
II (A540E)
Type T (08886 - 00405) or equivalent (A540H)
GENERAL INSTALLATION NOTES:
1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful
inspection before assembly because even a small nick could cause fluid leakage or affect
performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least fifteen
minutes.
3. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
AT-120- AUTOMATIC TRANSAXLEInstallation of Component Parts

(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

4. INSTALL GROMMETS ON INLET AND OUTLET
FITTINGS
5. CONNECT LIQUID TUBE TO COOLING UNIT INLET
FITTING
Torque the nut.
Torque: 140 kg±cm (10 ft±Ib, 14 N±m)
6. CONNECT SUCTION TUBE TO COOLING UNIT
OUTLET FITTING
Torque the nut.
Torque: 330 kg±cm (24 ft±ib, 32 N±m)
7. IF EVAPORATOR WAS REPLACED, ADD
COMPRESSOR OIL TO COMPRESSOR
Add 40 ± 50 cc (1.4 ± 1.7 fl.oz.)
Compressor oil: DENSOOIL 6,
SUNISO NO. 5GS or equivalent
8. CONNECT NEGATIVE CABLE TO BATTERY
9. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
10. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 700 g (1.3 ± 1.7 Ib)
REFRIGERANT LINES
(See page AC±12)
1. INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak detector. Replace, if necessary.
2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT
LOOSE
Tighten or replace as necessary.
REPLACEMENT OF REFRIGERANT
LINES
1. DISCHARGE REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fitting immediately to keep moisture
out of the system.
3. TIGHTENING TORQUE FOR O±RING AND BOLTED
TYPE FITTINGS
(See page AC±12)
4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
5. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 750 g (1.3 ± 1.7 Ib)
± AIR CONDITIONING SYSTEMCooling UnitAC±42

4. INSTALL GROMMETS ON INLET AND OUTLET
FITTINGS
5. CONNECT LIQUID TUBE TO COOLING UNIT INLET
FITTING
Torque the nut.
Torque: 140 kg±cm (10 ft±Ib, 14 N±m)
6. CONNECT SUCTION TUBE TO COOLING UNIT
OUTLET FITTING
Torque the nut.
Torque: 330 kg±cm (24 ft±lb, 32 N±m)
7. IF EVAPORATOR WAS REPLACED, ADD
COMPRESSOR OIL TO COMPRESSOR
Add 40 ± 50 cc (1.4 ± 1.7 fl.oz.)
Compressor oil: DENSOOIL 6,
SUNISO NO. 5GS or equivalent
8. CONNECT NEGATIVE CABLE TO BATTERY
9. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
10. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 700 g (1.3 ± 1.7 Ib)
REFRIGERANT LINES
(See page AC±12)
1. INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak detector. Replace, if necessary.
2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT
LOOSE
Tighten or replace as necessary.
REPLACEMENT OF REFRIGERANT
LINES
1. DISCHARGE REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fitting immediately to keep moisture
out of the system.
3. TIGHTENING TORQUE FOR O±RING AND BOLTED
TYPE FITTINGS
(See page AC±12)
4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
5. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 750 g (1.3 ± 1.7 Ib)
± AIR CONDITIONING SYSTEMRefrigerant LinesAC±42

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 work bench 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 tc keep all parts of that group in a separate container while proceeding with dis-
assembly, inspection, repair and assembly of other component groups.
Recommended fluid for the automatic transaxle is ATF type DEXRON) ll.
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean with any fluid passages and holes blown trough wit com-
pressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying,
automatic transmission 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, an(
reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for a 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 replaced.
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) (A140L and A140E)AT±78

8. REMOVE OIL PAN AND GASKET
(a) Remove the fifteen bolts.
(b) Remove the oil pan by lifting transmission case.
NOTICE: Do not turn the transmission over as this will con-
taminate the valve body with the foreign materials in the
bottom of the oil pan.
(c) Place the transmission on wooden blocks to prevent
damage to the tube bracket.
9. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel
chips. Look carefully at the chips and particles in the oil
pan and on the magnets to anticipate what type of wear
you will find in the transmission:
Steel (magnetic) ...bearing, gear and plate wear
Brass (non±magnetic) ...bushing wear (b) Remove the governor cover.
(c) Remove the governor body and thrust washer.
(d) Remove the plate washer and governor body
adaptor. 7. (A 140 L)
REMOVE GOVERNOR BODY
(a) Remove the two bolts and cover bracket.(c) Remove the speed sensor.
± AUTOMATIC TRANSAXLERemoval of Component Parts (A140L and A140E)AT±61