
3. USE OF PROPER O±RINGS AND SEALS
O±rings and seals used for conventional CFC12 air condi-
tioning systems cannot be used for HFC134a air conditioning
systems.
Always use genuine Toyota HFC134a system O±rings and
seals for HFC134a air conditioning systems.
If O±rings and/or seals for CFC12 air conditioning systems
are used by mistake in the connections of an HFC134a air
conditioning system, the O±ring and seals will foam and swell
resulting in leakage of refrigerant.
4. TIGHTEN CONNECTING PARTS SECURELY
Securely tighten the connecting parts to prevent leaking of
refrigerant gas.
wApply a few drops of compressor oil to O±ring fittings for
easy tightening and to prevent leaking of refrigerant
gas.
CAUTION: Apply only ND±OIL 8 compressor oil.
wTighten the nuts using 2 wrenches to avoid twisting the
tube.
wTighten the O±ring fittings or the bolted type fittings to
the specified torque.
5. INSERT PLUG IMMEDIATELY IN DISCONNECTED PARTS
Insert a plug immediately in the disconnected parts to pre-
vent the ingress of moisture and dust.
6. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL
IMMEDIATELY BEFORE INSTALLATION
7. DISCHARGE GAS IN NEW COMPRESSOR FROM
CHARGING VALVE BEFORE INSTALLING IT
If the gas in the new compressor is not discharged first, com-
pressor oil will spray out with gas when the plug is removed.
± AIR CONDITIONING SYSTEMGENERAL DESCRIPTIONAC±3

A340E (2JZ-GTE) AUTOMATIC TRANSMISSIONCOMPONENT PARTS --
AT-27
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 compo-
nent group. If a component group cannot be assembled because parts are being ordered, be sure to keep
all parts of that group in a separate container while proceeding with disassembly, inspection, repair and
assembly of other component groups.
Recommended ATF:
Type T-II or equivalent
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean and 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 accidentally spray-
ing automatic transmission fluid or kerosene on your face.
3. The recommended automatic transmission fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs,
and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New discs for the brakes and clutches that are to be used for replacement must be soaked in transmis-
sion fluid for at least 15 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 also be replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
AT0DD-03

A340E (2JZ-GTE) AUTOMATIC TRANSMISSIONCOMPONENT PARTS INSTALLATION -
AT-87
COMPONENT PARTS INSTALLATION
Disassembly, inspection and assembly of each component group have been indicated in the preceding
chapter. Before installation, make sure again that all component groups are assembled correctly.
If a problem is found in a certain component group during assembly, inspect and repair this group im-
mediately.
Recommended ATF:
Type T-II or equivalent
GENERAL NOTES:
1. The automatic transmission is composed of highly precision-finished parts, necessitating careful in-
spection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transmission fluid for at least 15 minutes.
3. Apply automatic transmission fluid on sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air-never use shop rags.
8. When working with FIPG material, you must observe the following.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket
surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surface with a non-residue solvent.
Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material
must be removed and reapplied.
AT0EY-02

A340E(Others) AUTOMATIC TRANSMISSIONCOMPONENT PARTS REMOVAL -
AT-25
15. REMOVE OIL PAN
NOTICE: Do not turn the transmission over as this will con-
taminate the valve body with any foreign matter at the bot-
tom on the pan.
(a) Remove the 19 bolts.
(b) Install the blade of SST between the transmission case
and oil pan, cut off applied sealer.
SST 09032-00100
NOTICE: Be careful not to damage the oil pan flange.
(c) Remove the pan by lifting the transmission case.
16. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect steel par-
ticles.
Carefully look at the foreign matter and particles in the
pan and on the magnets to anticipate the type of wear you
will find in the transmission.
Steel (magnetic) ... bearing, gear and clutch plate wear
Brass (non-magnetic) ... bushing wear
17. REMOVE OIL STRAINER AND GASKETS
(a) Remove the 3 bolts holding the oil strainer to the valve
body.
(b) Remove the oil strainer and 2 gaskets.
18. REMOVE OIL TUBES
Pry up both tube ends with a large screwdriver and re-
move the 2 oil tubes.

PRECAUTION
Take care to observe the doing precautions when performing inspections or removal and replacement of
body electrical related parts.
HEADLIGHT SYSTEM
wHalogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or
dropped. Hold a bulb only by its plastic or metal case.
Don't touch the glass part of a bulb with bare hands.
SRS (SUPPLEMENTAL RESTRAINT SYSTEM)
wWork must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº position
and the negative (±) terminal cable is disconnected from the battery.
wWhen disconnecting any of the connectors in the SRS, be sure to lock the ignition switch and disconnect
the negative (±) terminal cable from the battery first. Since the connectors are twin lock type connectors,
disconnect the connectors only after releasing the first stage lock.
wWhen connecting SRS connectors, be sure to lock them securely. (If the connectors are not locked
securely, the system may not operate when needed.)
wAlways store the steering wheel pad with the pad surface facing upward. (Storing the pad with its metallic
surface up may lead to a serious accident if the SRS inflates for some reason.)
wWhen installing the spiral cable, be sure the vehicle is in the straight ahead condition and confirm that the
spiral cable is in the neutral position when it is installed.
wINFORMATION LABELS (NOTICE) are attached to the periphery of the SRS components. Follow the
NOTICE.
AUDIO SYSTEM
wIf the negative (±) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 stations
stored in memory are erased, so be sure to note the stations and reset them after the battery terminal is
reconnected.
wIf the negative (±) terminal cable is disconnected from the battery, the ºANTI±THEFT SYSTEMº will operate
when the cable is reconnected, but the radio, tape player and CD player will not operate. Be sure to input
the correct ID number so that the radio, tape player and CD player can be operated again.
MOBILE COMMUNICATION SYSTEM
wIf the vehicle is equipped with a mobile communication system, refer to precautions in the IN section. BE±2
± BODY ELECTRICAL SYSTEMPRECAUTION

(c) Check the valve lift.
Valve lift:
8.5 mm (0.335 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve spring is tight when the thermostat is
fully closed.
If not closed, replace the thermostat.
THERMOSTAT INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion of
the water inlet.
2. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque:
2JZ±GE
8.8 NVm (90 kgfVcm, 78 in.Vlbf)
2JZ±GTE
21 NVm (210 kgfVcm, 15 ftVlbf)
(b) 2JZ±GTE:
Connect the lower radiator hose to the radiator.
3. 2JZ±GTE:
INSTALL ENGINE UNDER COVER
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR COOLANT LEAKS
RADIATOR
RADIATOR CLEANING
Using water or a steam cleaner, remove any mud and dirt
from the radiator core.
NOTICE: If using a high pressure type cleaner, be careful not
to deform the fins of the radiator core. If the cleaner nozzle
pressure is 2,942±3,432 kPa (30±35 kgf/cm
2, 427±498 psi), keep
a distance of at least 40 cm (15.75 in.) between the radiator core
and cleaner nozzle.
RADIATOR INSPECTION
1. REMOVE RADIATOR CAP
CAUTION: To avoid the danger of being burned, do not remove
the radiator cap while the engine and radiator are still hot, as
fluid and steam can be blown out under pressure.
EG±342± ENGINECOOLING SYSTEM

TRANSMISSION REMOVAL
Installation is in the reverse order of removal.
INSTALLATION HINT: After installation, check and in-
spect item as follow.
w Road test the vehicle.
1. REMOVE UPPER CONSOLE PANEL, SHIFT LEVER
BOOT AND SET BOLTS
(a) Remove the shift lever knob.
(b) Using a screwdriver, pry out the upper console panel.
(c) Remove the 4 set bolts.
(d) Remove the shift and select lever boot No.1 and No.2.
(e) Remove the 4 set bolts.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
2. RAISE VEHICLE
NOTICE: Be sure the vehicle is securely supported.
3. DRAIN TRANSMISSION OIL
Oil type:
TOYOTA GEAR OIL V160 or
ESSO ATF DEXRON[D±21065
Capacity:
1.8 liters (1.9 US qts. 1.6 lmp.qts)
4. REMOVE EXHAUST FRONT PIPE AND PIPE SUPPORT
BRACKET
(a) Remove the 2 nuts, heat insulator, oxygen sensor and
gasket.
(b) Remove the 2 bolts and nuts.
(c) Remove the 2 bolts and pipe support bracket.
Torque: 43 NVm (440 kgfVcm, 32 ftVlbf)
(d) Remove the 2 bolts and nuts.
(e) Remove the exhaust front pipe and gasket.
Torque: 58 NVm (590 kgfVcm, 43 ftVlbf)
± V160 MANUAL TRANSMISSIONASSEMBLY REMOVAL AND INSTALLATIONMT2±5

PROPELLER SHAFT REMOVAL
1. REMOVE OXYGEN SENSOR
(a) Remove the 2 bolts.
(b) Remove the oxygen sensor and heat insulator
2. REMOVE EXHAUST PIPE
(a) Remove the 2 bolts on the transmission side.
(b) Remove the 2 bolts and nuts, and pipe support bracket.
(c) Remove the 2 exhaust pipe support rings.
(d) Remove the 2 exhaust pipe support O±rings.
(e) Remove the exhaust pipe.
(f) Remove the gasket.
3. REMOVE HEAT INSULATOR
Remove the 4 nuts and heat insulator.
4. REMOVE CENTER FLOOR CROSSMEMBER BRACE
Normal Roof:
Remove the 4 bolts and crossmember brace.
Sport Roof:
Remove the 6 bolts and crossmember brace.
5. REMOVE PROPELLER SHAFT
2JZ±GTE:
(a) Using SST, loosen the adjusting nut until it can be turned by
hand.
SST 09922±10010
HINT: Use 2 of the same type of SST.
(b) Place the matchmarks on the differential companion flange
and flexible coupling.
(c) Remove the 3 bolts inserted in the differential companion
flange.
NOTICE: The bolts inserted in the propeller shaft com-
panion flange should not be removed.
(d) Separate the flexible coupling from the differential side.
HINT: If the flexible coupling cannot be easily separated by
hand, insert a screwdriver into the bolt hole of the flexible cou-
pling, as shown in the illustration, then pry the coupling out.
NOTICE: Do not bring the screwdriver blade in direct
contact with the flexible coupling's rubber portion.
± PROPELLER SHAFTPROPELLER SHAFTPR±7