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Page of 29 Manual Transaxle Assembly ZOOM SIZED FOR PRINT Page of 29 ZOOM SIZED FOR PRINT Page of 29 ZOOM SIZED FOR PRINT DISASSEMBLY a) REMOVE FILLER PLUG AND DRAIN PLUG WITH GASKETS Torque: 39 Nm (400 kgf-cm, 29 ft lbs.) REMOVE VEHICLE SPEED SENSOR Remove the bolt and vehicle speed sensor Torque: 11 Nm (115 kgf-cm, ft lbs.) b) Using a small screwdriver, remove the clip from the vehicle speed sensor Page of 29 Remove the vehicle speed sensor driven gear from the speed sensor c) d) Using a small screwdriver, remove the O -ring from the vehicle speed sensor REMOVE BACK-UP LIGHT SWITCH WITH GASKET Torque: 40 Nm (410 kgf-cm, 30 ft lbs.) REMOVE CONTROL CABLE BRACKET Remove the bolts and control cable bracket Torque: 25 Nm (250 kgf-cm, 18 ft lbs.) ZOOM REMOVE CONTROL SHAFT ASSEMBLY Remove the nuts, wave washer and control shaft assembly Torque: 12 Nm (120 kgf-cm, ft lbs.) ZOOM SIZED FOR PRINT SIZED FOR PRINT REMOVE SELECTING BELLCRANK ASSEMBLY a) Remove the bolts and selecting bellcrank assembly Torque: 25 Nm (250 kgf-cm, 18 ft lbs.) NOTICE: l l At the time of reassembly, please refer to the following item Fit the selecting bellcrank assembly pin part with the dust cover into a groove in the control shift lever b) Remove the control bellcrank dust cover from the selecting bellcrank assembly NOTICE: Page of 29 l l At the time of reassembly, please refer to the following item Apply MP grease to the inside circumferential surface of the control bellcrank dust cover REMOVE CONTROL SHIFT LEVER AND DUST BOOT ZOOM SIZED FOR PRINT a) Remove the nut and wave washer Torque:12 Nm (120 kgf-cm, ft lbs.) ZOOM SIZED FOR PRINT b) Using a pin punch and hammer, drive out the lever lock pin NOTICE: l l At the time of reassembly, please refer to the following item When fixing the lever lock pin, properly position the shaft groove c) Remove the control shift lever and dust boot NOTICE: l l l At the time of reassembly, please refer to the following items Install the dust boot into a groove in the control shift lever Be sure to install the dust boot in the correct direction, as shown in the illustration Page of 29 ZOOM a) SIZED FOR PRINT REMOVE PLUG, LOCK BALL ASSEMBLY AND CONTROL SHAFT COVER ASSEMBLY Using a hexagon wrench, remove the plug and gasket Torque: 39 Nm (400 kgf-cm, 29 ft lbs.) b) Remove the lock ball assembly Sealant: Part No 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 Nm (300 kgf-cm, 22 ft lbs.) c) Remove the bolts and control shaft cover assembly with the gasket Sealant: Part No 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 Nm (200 kgf-cm, 14 ft lbs.) ZOOM a) SIZED FOR PRINT DISASSEMBLE CONTROL SHAFT COVER ASSEMBLY Using snap ring pliers, remove the snap ring b) Remove the No.3 select spring seat and compression spring Page of 29 ZOOM 10 SIZED FOR PRINT REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY a) Remove the shift and select lever shaft assembly NOTICE: l l At the time of reassembly, please refer to the following Item Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely b) Remove the select spring seat and compression spring from the shift and select lever shaft assembly ZOOM 11 a) SIZED FOR PRINT REMOVE TRANSMISSION CASE COVER Remove the bolts Torque: 18 Nm (185 kgf-cm, 13 ft lbs.) b) Carefully tap the projection of the transmission case cover with a brass bar and hammer and remove it HINT: At the time of reassembly, please refer to the following item Apply FIPG to the transmission case side, as shown in the illustration FIPG: Part No 08826-00090, THREE BOND 1281 or equivalent Page of 29 ZOOM 12 INSPECT 6TH GEAR THRUST CLEARANCE Using a dial indicator, measure the thrust clearance Standard clearance:0.10 0.60 mm (0.0039 - 0.0236 inch) Maximum clearance: 0.60 mm (0.0236 inch) ZOOM 13 14 SIZED FOR PRINT SIZED FOR PRINT INSPECT 6TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance Standard clearance:0.009 - 0.050 mm (0.0003 - 0.0020 inch) Maximum clearance: 0.050 mm (0.0020 inch) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING, 6TH DRIVEN GEAR AND SPACER ZOOM SIZED FOR PRINT a) Using screwdrivers and a hammer, tap out the snap ring Page of 29 ZOOM SIZED FOR PRINT HINT: l l At the time of reassembly, please refer to the following item Select a snap ring from the table that will make the thrust clearance of the output shaft rear radial ball bearing less than 0.1 mm (0.0039 inch) ZOOM SIZED FOR PRINT b) Using SST, remove the rear radial ball bearing and 6th driven gear SST 09950 -40011 (09951 -04010, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011) HINT: l At the time of reassembly, please refer to the following items ZOOM l SIZED FOR PRINT Using SST and a hammer, drive in the 6th driven gear SST 09325-12010 Page 10 of 29 NOTICE: Be sure to install the 6th driven gear in the correct direction, as shown in the illustration ZOOM l SIZED FOR PRINT Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer SST 09517-12010 c) Remove the spacer 15 REMOVE INPUT SHAFT REAR RADIAL BALL BEARING AND 6TH GEAR ZOOM SIZED FOR PRINT a) Using screwdrivers and a hammer, tap out the snap ring ZOOM SIZED FOR PRINT HINT: l At the time of reassembly, please refer to the following item 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Part of ZOOM Page 14 of 20 SIZED FOR PRINT 37 INSTALL CHECK BALL BODY AND SPRING 38 INSTALL TRANSAXLE SOLENOID WIRE ZOOM a Coat a new O-ring with ATF, install it to the transaxle solenoid wire ZOOM b SIZED FOR PRINT SIZED FOR PRINT Install the solenoid wire retaining bolt Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Part of ZOOM Page 15 of 20 SIZED FOR PRINT 39 INSTALL APPLY GASKET a ZOOM Coat apply gaskets with ATF and install them to the transaxle case SIZED FOR PRINT 40 INSTALL VALVE BODY ASSEMBLY a b ¡ ¡ Align the groove of the manual valve with the pin of lever Install the 17 bolts Torque: 11 Nm (110 kgf-cm, ft lbs.) NOTICE: Push the valve body against the accumulator piston spring and the check ball body to install It Tighten those bolts marked by * in the illustration first temporarily because they are positioning bolts HINT: Each bolt length is indicated Bolt length: Bolt A: 25 mm (0.984 inch) Bolt B: 41 mm (1.614 inch) Bolt C: 45 mm (1.771 inch) 41 INSTALL OIL STRAINER http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Part of ZOOM a SIZED FOR PRINT Install the oil strainer and bolts to the valve body Torque: 11 Nm (110 kgf-cm, ft lbs.) ZOOM c d SIZED FOR PRINT Coat new gasket with ATF, install it to the oil strainer ZOOM b Page 16 of 20 SIZED FOR PRINT Connect the solenoid connectors Install the ATF temperature sensor, lock plate and bolt Torque: 6.6 Nm (67 kgf-cm, 58 inch lbs.) 42 INSTALL OIL PAN http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Part of ZOOM a b SIZED FOR PRINT Install the magnets in the oil pan Apply seal packing or equivalent to the new 18 bolts Seal packing: THREE BOND 2430 or equivalent ZOOM c Page 17 of 20 SIZED FOR PRINT Install a new gasket, oil pan and 18 bolts to the transaxle case Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.) NOTICE: Because the bolts should be seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application ZOOM SIZED FOR PRINT 43 INSTALL SPEED SENSOR a b Coat new O-rings with ATF, install it to the sensors Install the sensors with bolts to the transaxle case Torque: 11 Nm (110 kgf-cm, inch lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Part of ZOOM Page 18 of 20 SIZED FOR PRINT 44 INSTALL UNION a b ZOOM Coat new O-rings with ATF, install them to the unions Install the unions to the transaxle case Torque: 27 Nm (276 kgf-cm, 20 ft lbs.) SIZED FOR PRINT 45 INSTALL TRANSAXLE CASE PLUG NO.1 a b Coat a new O-ring with ATF, install it to the transaxle case plug No Install the transaxle case plug No.1 to the transaxle case Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) 46 INSTALL PARK/NEUTRAL POSITION SWITCH ZOOM a SIZED FOR PRINT Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the adjusting bolts http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Part of b Install the new nut stopper and nut Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.) ZOOM c SIZED FOR PRINT Temporarily install control shaft lever ZOOM d e Page 19 of 20 SIZED FOR PRINT Turn the lever counterclockwise until it stops, them turn it clockwise notches Remove the control shaft lever ZOOM SIZED FOR PRINT f Align the groove with neutral basic line g Tighten the bolts Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Part of ZOOM h SIZED FOR PRINT Using a screwdriver, stake the nut with the nut stopper ZOOM i Page 20 of 20 SIZED FOR PRINT Install control shaft lever, washer and nut Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation Page of Removal and Installation ZOOM SIZED FOR PRINT REMOVAL REMOVE HOOD Torque: 13 Nm (130 kgf-cm, ft lbs.) REMOVE BATTERY REMOVE ECM AND ECM CASE Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.) REMOVE ECM BRACKET Torque: Bolt: 18 Nm (185 kgf-cm, 13 ft lbs.) Nut: 12 Nm (120 kgf-cm, ft lbs.) REMOVE AIR CLEANER ASSEMBLY REMOVE NO.2 CYLINDER HEAD COVER Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation ZOOM 10 11 Page of SIZED FOR PRINT REMOVE GROUND CABLES Torque: 18 Nm (185 kgf-cm, 13 ft lbs.) DISCONNECT CONTROL CABLE FROM CLAMP DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR REMOVE VEHICLE SPEED SENSOR CONNECTOR ZOOM SIZED FOR PRINT 12 REMOVE UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE Torque: 64 Nm (650 kgfcm, 47 ft lbs.) ZOOM SIZED FOR PRINT 13 DISCONNECT SOLENOID CONNECTOR AND PARK/NEUTRAL POSITION SWITCH CONNECTOR Disconnect the solenoid connector and park/neutral position switch connector 14 DISCONNECT CONTROL CABLE http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation a) Page of Remove the nut from the control shift lever Torque: 12 Nm (120 kgf-cm, ft lbs.) b) Remove the clip and disconnect the control cable 15 REMOVE BOLT AND DISCONNECT RADIATOR RESERVOIR Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.) ZOOM SIZED FOR PRINT 16 REMOVE STARTER a) Remove the nut and wire, and disconnect the connector b) Remove the bolts and starter Torque: 37 Nm (378 kgf-cm, 28 ft lbs.) 17 REMOVE LH, RH, CENTER ENGINE UNDER COVERS ZOOM SIZED FOR PRINT 18 DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque: 54 Nm (550 kgf-cm, 40 ft lbs.) 19 REMOVE LH AND RH DRIVE SHAFTS http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation ZOOM Page of SIZED FOR PRINT 20 DISCONNECT LH AND RH STABILIZER BAR LINKS FROM SHOCK ABSORBER Torque: 44 Nm (450 kgfcm, 32 ft lbs.) ZOOM SIZED FOR PRINT 21 REMOVE BOLTS AND DISCONNECT PS GEAR ASSEMBLY HINT: Support the PS gear assembly securely Torque: 45 Nm (459 kgf-cm, 33 ft lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation ZOOM Page of SIZED FOR PRINT 22 REMOVE SUSPENSION MEMBER a) Remove the bolts and nuts Torque: Bolt A: 157 Nm (1,601 kgf-cm, 116 ft lbs.) Bolt B: 113 Nm (1,152 kgf-cm, 83 ft lbs.) Bolt C: 52 Nm (530 kgf-cm, 38 ft lbs.) Bolt D: 39 Nm (398 kgf-cm, 29 ft lbs.) Nut: 52 Nm (530 kgf-cm, 38 ft lbs.) b) Remove the suspension member ZOOM SIZED FOR PRINT 23 REMOVE ENGINE REAR MOUNTING INSULATOR Remove the bolt and engine rear mounting insulator Torque: 87 Nm (890 kgf-cm, 64 ft lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation ZOOM Page of SIZED FOR PRINT 24 ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS a) Disconnect the PCV hoses b) Install the No.1 and No.2 engine hangers in the correct direction Parts No No.1 engine hanger: 12281-88600 No.2 engine hanger: 12282-88600 Bolt: 91512-61020 Torque: 38 Nm (387 kgf-cm, 28 ft lbs.) c) Attach the engine chain hoist to the engine hangers CAUTION: Do not attempt to hang the engine by hooking the chain to any other part ZOOM SIZED FOR PRINT 25 REMOVE UPPER SIDE ENGINE LEFT MOUNTING, NUT AND BOLT Torque: 80 Nm (816 kgf-cm, 59 ft lbs.) http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation ZOOM Page of SIZED FOR PRINT 26 REMOVE OIL COOLER HOSE Loosen the clips and disconnect the oil cooler hoses 27 SUPPORT TRANSAXLE WITH A JACK ZOOM SIZED FOR PRINT 28 REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT Turn the crankshaft to gain access and remove the bolts holding the crankshaft pulley set bolt with a wrench Torque: 41 Nm (418 kgf-cm, 30 ft lbs.) HINT: ¡ ¡ ZOOM At the time of installation, please refer to the following item First install black colored bolt and then other bolts SIZED FOR PRINT 29 REMOVE TRANSAXLE ASSEMBLY http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 2000 Toyota Celica GT -S L4-1762cc 1.8L DOHC MFI - Removal and Installation a) Page of Remove the bolts Torque: A bolt: 46 Nm (470 kgf-cm, 34 ft lbs.) B bolt: 23 Nm (230 kgf-cm, 17 ft lbs.) b) Separate the transaxle from engine, and lower the transaxle INSTALLATION ZOOM SIZED FOR PRINT CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using calipers and a straight edge, measure the distance between the installed surface and the front surface of the transaxle housing Correct distance: More than 13.3 mm (0.524 inch) TRANSAXLE INSTALLATION Installation is in the reverse order of removal HINT: ¡ ¡ ¡ ¡ After installation, adjust the shift control cable and park/neutral position switch Fill ATF and check the fluid level Perform the test drive of the vehicle Adjust the hood http://www.alldatadiy.com/alldata/AFI~V1046639~C34697~R0~OD~N/0/77993956/788 12/13/2001 ... radial ball bearing and 6th driven gear SST 09950 -4 0011 (09951 -0 4010, 0995 2-0 4010, 0995 3-0 4030, 0995 4-0 4010, 0995 5-0 4021, 0995 7-0 4010, 0995 8-0 4011) HINT: l At the time of reassembly, please... the rear radial ball bearing and 6th gear SST 09950 -4 0011 (09951 -0 4010, 0995 2-0 4010, 0995 3-0 4030, 0995 4-0 4010, 0995 5-0 4021, 0995 7-0 4010, 0995 8-0 4011) ZOOM SIZED FOR PRINT HINT: l l At the time... a press, install a new input shaft front bearing SST 0995 0-6 0010 (09951 -0 0400), 0995 0-7 0010 (0995 1-0 7150) Drive in depth: - 0.3 mm (0 - 0.012 inch) NOTICE: Be sure to install a new bearing in