1986 TOYOTA CAMRY V20 torque

60. INSTALL NEUTRAL START SWITCH
(a) Install the neutral start switch to the manual valve shaft.
(b) Install the seal gasket and locking plate.
(c) Tighten the nut and stake it with the locking plate.
Torque: 70 kg±cm (61 in.±Ib. 6.9 N±m)
56. (A140E)
INSTALL SOLENOID WIRING RETAINING PLATE
57. INSTALL THROTTLE CABLE RETAINING PLATE
58. INSTALL FILLER TUBE AND DIPSTICK
59. INSTALL SOLENOID
(a) Coat the O±rings with ATF and push the tip of solenoid
into the hole.
(b) Tighten the two bolts evenly and gradually.
61. ADJUST NEUTRAL START SWITCH
(a) Align the groove and return neutral basic line. 55. INSTALL COVER BRACKET
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A140L and A140E)AT±181

63. INSTALL UNION AND ELBOW
(a) Coat a new O±rings with ATF.
(b) Install the O±rings to the union and elbow.
(e) Install the union and elbow to the transaxle case.
Torque: 275 kg±cm (20 ft±Ib, 27 N±m)
(b) Lock the switch with two bolts.
Torque: 55 kg±cm (48 in.±Ib, 5.4 N±m)
62. INSTALL MANUAL SHIFT LEVER
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A140L and A140E)AT±182

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.
± AUTOMATIC TRANSAXLEDescription (A540E and A540H)AT±184

(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 A241 H automatic transaxle on the Corolla All±TRAC/4WD Station Wagon. The fluid pres-
sure 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 mainte-
nance. Instructions concerning these handling methods are given on page IN±8.
± AUTOMATIC TRANSAXLEDescription (A540E and A540H)AT±185

Shift cable out of adjustment
Valve body or primary regulator
faulty
Parking lock pawl faulty
Torque converter faulty
Converter drive plate broken
Oil pump intake screen blocked
Transaxle faulty
Shift cable out of adjustment
Throttle cable out of adjustment
Valve body faulty
Solenoid valve faulty
Transaxle faulty Throttle cable out of adjustment
Valve body or primary regulator faulty
Accumulator pistons faulty
Transaxle faultyInspect parking lock pawl
Replace torque converter
Replace drive plate
Clean screen
Disassemble and inspect
transaxle
Adjust shift cable
Adjust throttle cable
Inspect valve body
Inspect solenoid valve
Disassemble and inspect
transaxle Delayed 1±2, 2±3 or
3±O/D up±shift, or
down±shifts from
O/D±3 or 3±2 and
shifts back to O/D or 3Replace fluid
Replace torque converter
Disassemble and inspect
transaxle
Adjust shift cable
Inspect valve body
Disassemble and inspect
transaxle
Adjust shift cable
Inspect valve body
Disassemble and inspect
transaxle Shift cable out of adjustment
Valve body faulty
Transaxle faultyShift cable out of adjustment
Manual valve and lever faulty
Transaxle faulty
Inspect electronic control
Inspect valve body
Inspect solenoid valveInspect accumulator pistons
Disassemble and inspect
transaxle
General Troubleshooting
Electronic control faulty
Valve body faulty
Solenoid valve faultyFluid contaminated
Torque converter faulty
Transaxle faulty
Slips on 1±2, 2±3
or
3±O/D up±shift, or
slips or shudders
on accelerationVehicle does not move in
any forward range or
reverse
Drag, binding or tieup on
1±2, 2±3 or 3±
O/D up±shiftHarsh engagement into
any drive range
AT±201
AT±201
AT±308
AT±218
AT±236 Adjust throttle cable
Inspect valve body
AT±219 Adjust shift cable
Inspect valve body
Shift lever position
incorrect Fluid discolored
or smells burntAT±200
AT±381
AT±236
AT±203
AT±308
AT±218AT±201
AT±308
AT±236
AT±201
AT±308
AT±236AT±219 AT±201
AT±308AT±392
AT±381AT±201
AT±308
AT±403
AT±236 Possible cause
Problem
Remedy
1± AT±236A540 H A540EPage
± AUTOMATIC TRANSAXLETroubleshooting (Basic Troubleshooting) (A540E and
A540H)AT±187

S. INSPECT AND ADJUST THROTTLE CABLE
(a) Depress the accelerator pedal all the way and check that
the throttle valve opens fully.
HINT: If the valve does not open fully, adjust the accelera-
tor cable.
(b) Fully depress the accelerator pedal.
(c) Measure the distance between the end of the boot and
stopper on the cable.
Standard distance: 0 ± 1 mm (0 ± 0.04 in.)
If the distance is not standard, adjust the cable by the ad-
justing nuts.
7. INSPECT AND ADJUST SHIFT CABLE
When shifting the shift lever from the ±N position to other
positions, check that the lever can be shifted smoothly and
accurately to each position and that the position indicator
correctly indicates the position.
If the indicator is not aligned with the correct position, carry
out the following adjustment procedures.
(a) Loosen the swivel nut on manual shift lever.
(b) Push the manual lever fully toward the right side of the ve-
hicle.
(c) Return the lever two notches to NEUTRAL position.
(d) Set the shift lever to N.
(e) While holding the lever lightly toward the R range side,
tighten the swivel nut.
8. ADJUST NEUTRAL START SWITCH
If the engine will start with the shift selector in any range
other than N or P range, adjustment is required.
(a) Loosen the neutral start switch bolts and set the shift se-
lector to the N range.
(b) Align the groove and neutral basic line.
(c) Hold in position and tighten the bolts.
Torque: 55 kg±cm (48 in.±lb, 5.4 N±m)
9. INSPECT IDLE SPEED IN RANGE)
Idle speed: 700 rpm
± AUTOMATIC TRANSAXLETroubleshooting (Preliminary Check) (A540E and A540H)AT±201

ROAD TEST (A540E and A540H)
NOTICE: Perform the test at normal operating fluid temperature
(122 ± 176°F or 50 ± 80°C).
1. D RANGE TEST IN NORM AND PWR PATTERN
RANGES
Shift into the D range and hold the accelerator pedal
constant at the full throttle valve opening position.
Check the following:
(a) 1±2, 2±3 and 3±O/D up±shifts should take place, and shift
points should conform to those shown in the automatic
shift schedule. (See page AT±230)
Conduct a test under both Normal and Power. patterns.
HINT:
wThere is no O/D up±shift and lock±up when the coolant
temp. is below 140
°F (60°C) (A540E) or 122°I= (50°C)
(A540H).
wWhen the coolant temp. is below 140°F (600C) or
122°F (50°C) (A540H), the shift point is lower than specified in
the automatic shift schedule.
EVALUATION
(1) If there is no 1 ± 2 up±shift:
wNo. 2 solenoid is stuck
w1±2 shift valve is stuck
(2) If there is no 2 ± 3 up±shift:
wNo. 1 solenoid is stuck
w2±3 shift valve is stuck
(3) If there is no 3 ± O/D up±shift:
w3±4 shift valve is stuck
(4) If the shift point is defective:
wThrottle valve, 1±2 shift valve, 2±3 shift valve, 3±4
shift valve etc., are defective
(5) If the lock±up is defective:
wLock±up solenoid is stuck .
wLock±up relay valve is stuck
(b) In the same manner, check the shock and slip at the 1
±2, 2 ± 3 and 3 ± O/D up±shifts.
EVALUATION
If the shock is excessive:
wLine pressure is too high
wAccumulator is defective
wCheck ball is defective
(c) Run at the D range lock±up or 0/C) gear and check for abnor-
mal noise and vibration.
HINT: The check for the cause of abnormal noise and vibra-
tion must be make with extreme care as it could also be due
to loss of balance in the drive shaft, tire, torque converter,
etc.
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±227

3. INSTALL TORQUE CONVERTER MOUNTING BOLTS
(a) Clean the threads of the bolts with the gasoline.
(b) Coat the threads of the bolts with sealer.
Sealer: Part No. 08833±00070, THREE BOND 1324
or equivalent.
(c) Tighten the bolts evenly.
Torque: 280 kg±cm (20 ft±Ib, 27 N±m)
2. CHECK TORQUE CONVERTER INSTALLATION
Using a scale and a straight edge, measure from the
installed surface to the front surface of the transaxle
housing.
Correct distance: 23.0 mm I0.906 in.) or more
4. (A540H, Transfer)
INSPECT MODE SELECT LEVER POSITION
After finishing inspection or repair the transaxle, be sure
the mode select lever position to FREE mode and at-
tach the lock bolt.
(MAIN POINT OF INSTALLATION)
1. INSTALL TORQUE CONVERTER IN TRANSAXLE
± AUTOMATIC TRANSAXLERemoval and Installation of Transaxle (A540E and
A540H)AT±235