1986 TOYOTA CAMRY V20 service

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

TransferDriven pinion preload (at starting)
Total preload (at starting)
Ring gear backlash
Driven pinion bearing cage
Driven pinion preload (at starting)
New bearing
Reused bearing
Center differential side gear backlash0.9 - 1.4 kg 2.0 - 3.1 lb 8.8 - 13.7 N
0.5 - 0.9 kg 1.1 - 2.0 lb 4.9 - 8.8 N
0.13 - 0.18 mm 0.0051 - 0.0071 in.
1.8 - 2.9 kg 4.0 - 6.4 lb 18 - 28 N
0.9 - 1.4 kg 2.0 - 3.1 lb 9 - 13 N
0.05 - 0.20 mm 0.0020 - 0.0079 DifferentialDrive pinion preload (at staring)
New bearing
Reused bearing
Total preload (at starting)
New bearing
Reused bearing
Pinion to side gear backlash
Side gear thrust washer thickness
Mark
A
B
C
D
E
F
G
Side bearing adjusting shim thickness
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
Differential end play2.00 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
0.18 - 0.82 mm0.0787 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.
0.0071 - 0.0323 in. 0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in. 1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 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
2.3 - 3.7 kg-cm 2.0 - 3.2 in.-lb 0.2 - 0.4 N-m
1.2 - 1.9 kg-cm 1.0 - 1.6 in.-lb 0.1 - 0.2 N-m
0.05 - 0.20 mm 0.0020 - 0.0079 in.
Specifications (Cont'd)
TRANSFER (A540H)
Specifications
A-6- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

Transfer
(Cont'd)Center differential left side gear
thrust washer thickness
Center differential side gear
thrust clearance
Center differential right side gear
thrust washer thickness 0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0071 - 0.0248 in.
0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0571 in.
0.0591 in. 1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
0.18 - 0.63 mm
1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
1.45 mm
1.50 mm
Transfer lower valve body springFree length
mm (in.)Coil outer
diameter
mm (in.)Total
No. of
coilsColor
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve32.2 (1.272)
28.9 (1.138)
28.9 (1.138)7.6 (0.299)
7.0 (0.276)
7.0 (0.276)16
14
14None
None
None
Transfer lower valve body retainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve6.5 (0.256)
=
=5.0 (0.197)
=
=3.2 (0.126)
=
=
Center differential plate washer
2.13 mm
2.16 mm
2.19 mm
2.22 mm
2.25 mm
2.28 mm
2.31 mm
2.34 mm
2.37 mm
2.40 mm0.0839 in.
0.0850 in.
0.0862 in.
0.0874 in.
0.0886 in.
0.0898 in.
0.0909 in.
0.0921 in.
0.0933 in.
0.0945 in.
Specifications (Cont'd)
Mark
A
B
C
D
E
F
G
H
J
Mark
A
B
C
D
E
F
G
H
J
K
L
Mark
71
72
73
74
75
76
77
78
79
80
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-7

Part tightenedkg-cmft-lb N-m
Oil cooler pipe union and elbow
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 carrier cover
Oil pump body y Stator shaft
Upper valve body y Lower valve body
Front differential right case y Front differential left case
Ring gear y Ring gear mounting case
Transfer right case retainer y Transfer right case
Transfer right case y Adjusting nut lock plate lock bolt
Transfer right case y Transfer left case
Transfer right case y Mode select lever and rod275
50
11 0
100
225
250
195
400
100
67
340
1,260
300
73
450
55
11 520
43 in.-lb
8
7
16
18
14
29
7
58 in.-lb
25
91
22
63 in.-lb
33
48 in.-lb
827
4.9
11
10
22
25
19
39
10
6.6
33
124
29
7.2
44
5.4
11 Transfer
(Cont'd)81
82
83
84
85
86
87
88
89
90
91
92
93
94
Mark
A
B
C
D
E
F
G
H
J
K Ring gear adjusting shim2.43 mm
2.46 mm
2.49 mm
2.52 mm
2.55 mm
2.58 mm
2.61 mm
2.64 mm
2.67 mm
2.70 mm
2.73 mm
2.76 mm
2.79 mm
2.82 mm
0.30 mm
0.33 mm
0.36 mm
0.39 mm
0.42 mm
0.45 mm
0.48 mm
0.51 mm
0.54 mm
0.57 mm0.0957 in.
0.0969 in.
0.0980 in.
0.0992 in.
0.1004 in.
0.1016 in.
0.1028 in.
0.1039 in.
0.1051 in.
0.1063 in.
0.1075 in.
0.1087 in.
0.1098 in.
0.1110 in.
0.0118 in.
0.0130 in.
0.0142 in.
0.0154 in.
0.0165 in.
0.0177 in.
0.0189 in.
0.0201 in.
0.0213 in.
0.0224 in.
Specifications (Cont'd)
Torque Specifications
A-8- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

ItemCapacity
Classification
Liters US qts
Imp. qts
Automatic
transaxle fluid
(w/o Differential
oil)A540E
Dry fill
Drain and refill5.9
2.56.2
2.65.2
2.2ATF DEXRON
II
A54H
Dry fill
Drain and refill7.0
3.37.4
3.56.2
2.9ATF type T (08886 - 00405) or equivalent
Differential oil
(w/ Automatic transaxle)
SV21 series
VZV21 series1.6
1.01.7
1.11.4
0.9ATF DEXRON
II
Transfer oil (A540H)
0.7
0.74 0.62
Recommended oil
Oil grade: API GL-5
Viscosity: SAE 75W-90 or 80W-90
SAE 90W
[above -18°C (0°F)]
SAE 80W
[below -18°C (0°F)]
Transaxle oil E50 (08885 - 80206) or
equivalent
Part tightenedkg-cm ft-lbN-m
Transfer right case y Oil strainer
Transfer left case y Rear wheel speed sensor
Transfer left case y Transfer inspection hole cover
Transfer left case y Drain plug
Transfer left case y Driven pinion bearing cage
Driven pinion bearing cage y Transfer extension housing
Transfer extension housing y Dynamic damper
Transfer right case y Oil pump cover
Transfer ring gear y Ring gear mounting case
Center differential control solenoid y Transfer valve body
Transfer valve body y Transfer left case
Neutral start switch bolt
Neutral start switch nut
Transfer assembly y Transaxle case48 in.-lb
48 in.-lb
12
29
29
19
19
69 in.-lb
71
10
8
48 in.-lb
61 in.-lb
51 55
55
160
400
400
260
260
80
985
145
11 0
55
70
7005.4
5.4
16
39
39
25
25
7.8
97
14
11
5.4
6.9
69
Torque Specifications (Cont'd)
LUBRICANT
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-9

(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

To evacuate and charge system
To perform electrical diagnosis
To perform electrical diagnosis
To perform electrical diagnosis
To remove and install pressure plate
To remove pressure plate
To remove and install rotor and stator Air conditioner service tool set
Ohmmeter
Voltage meter
Ammeter
Magnetic clutch stopper
Magnetic clutch remover
Snap ring pliers (External type)
SPECIAL TOOLS AND EQUIPMENT
SSM (SPECIAL SERVICE MATERIALS)
07110±58011
07112±76060
07112±66040
07114±84020
DENSOOIL 6,
SUNlSO No. 5GS or equivalent07117±68040
Compressor
Part NameSST No.
Part No.
Use etc. Tool
Use
± AIR CONDITIONING SYSTEMSpecial Tools and EquipmentAC±15