A/T Assembly Installation (K20Z: A/T)

A/T Assembly Installation

Special Tools Required
Engine support hanger (  AAR-T1256-J00)


This special tool is available from Snap-on Tools International, LLC. Asia Pacific Division

NOTE: Use fender covers to avoid damaging painted surfaces.

1.Install the air cleaner housing mounting bracket.

 

2.Install the torque converter (A) on the mainshaft (B) with the new O-ring (C).

 

3.Install the 14 x 20 mm dowel pins (D) in the torque converter housing.

4.Place the transmission on the jack, and raise the transmission to the engine level.

5.Install the rear transmission housing mounting bolts.

 

6.Install the front transmission housing mounting bolts.

 

7.Install the upper transmission housing mounting bolts.

 

8.Secure the transmission mount bracket on the transmission housing with the new mounting bolts.

 

9.Install the new set ring (A) on the intermediate shaft (B).

 

10.Clean the areas where the intermediate shaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. Apply intermediate shaft splines with ATF, then install the intermediate shaft, be sure not to allow dust or other foreign particles to enter the transmission.

11.Install the intermediate shaft cover (C) with installing the mounting bolts loosely.

12.First tighten the right upper bolt (D) on the cover, then right lower bolt (E), and lastly the left bolt (F).

13.Install the new set ring (A) on the left driveshaft (B).

 

14.Clean the areas where the left driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. Then install the left driveshaft, be sure not to allow dust or other foreign particles to enter the transmission. Turn the steering knuckle fully outward, and slide the driveshaft into the differential until you feel its set ring fully engage the side gear.

15.Apply right driveshaft inboard-joint splines with the recommended grease.

16.Slide the right driveshaft over the intermediate shaft splines until you feel the driveshaft fully engage the intermediate shaft set ring.

17.Attach the torque converter to the drive plate with eight bolts (A). Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotate freely.

 

18.Install the torque converter cover (B).

19.Install the control lever (A) over the control shaft (B).

 

20.Secure the control lever with the new lock washer (C) and the lock bolt (D), then bend the lock tab of the lock washer against the bolt head.

21.Install the shift cable cover (E), and install the shift cable holder (F) on the cover.


22.Support the front subframe with a wood piece and a jack, and lift it up to the body.

 

23.Loosely install the new subframe mounting bolts.

 

24.Align the reference marks (A) on the subframe (B) with the edge (C) of the body, and tighten the mounting bolts to the specified torque.

 

25.Secure the lower torque rod with the new bolts.

 

26.Position the steering gearbox on the gearbox mounting bracket of the subframe.

27.Install the gearbox stiffener (A) in the direction shown. Install the steering gearbox mounting bolt (B) and stiffener mounting bolt (C), and tighten the bolts loosely.

NOTE: Steps 27 thru 31 describe gearbox installation for the RHD model; LHD model is symmetrical.

 

28.Install the stiffener (A), steering gearbox mounting bolt (B), and stiffener mounting bolt (C), and tighten the bolts loosely.

 

29.Install the steering gearbox bracket mounting bolts.

 

30.Tighten the steering gearbox mounting bolts and stiffener mounting bolts to the specified torque.

31.Install the bolt securing the harness clamp bracket.

 

32.Install both body mount brackets with the new bolts.

 

33.Install both lower arms (A) to both ball joints (B), and loosely install the new mounting nuts and bolts.

 

34.Tighten the nuts and bolts to 59 N·m (6.0 kgf·m, 43 lbf·ft) in the following order; the nut on the front (C), the nut on the rear (D), then the bolt (E).

35.Install the exhaust pipe mounting rubber.

 

36.Connect the ATF cooler hose (A) to the ATF cooler (B), and secure the hose with the clip (C).

 

37.Remove the hanger plate (A) and bolt (B), and install the harness cover bracket (C) on the engine.

 

38.Remove the engine support hanger.

39.Connect the ATF cooler hoses (A) to the ATF cooler lines (B), and secure the hoses with the clips (C).

 

40.Secure the harness clamp bracket (A) on the transmission hanger(B) with the bolt.

 

41.Install the water hose (A) to its clamp (B) at the mark (C).

 

42.Connect the shift solenoid harness connector (A), A/T clutch pressure control solenoid valve B connector, and solenoid valve C connector, and install the harness clamps (D) on the clamp brackets (E).

 

43.Connect the 3rd clutch transmission fluid pressure switch connector.

 

44.Connect the output shaft (countershaft) speed sensor connector (A) and input shaft (mainshaft) speed sensor connector (B), and install the harness clamp (C) on its clamp bracket (D).

 

45.Install the transmission range switch connector (E) on the connector bracket (F), and connect the connector.

46.Connect the A/T clutch pressure control solenoid valve A connector and 2nd clutch transmission fluid pressure switch connector (B), and install the harness clamps (C) on the clamp brackets (D).

 

47.Install the harness cover on its bracket.

 

48.Refill the transmission with ATF.

49.Install the battery base and resonator.

50.Install the air cleaner housing and intake air duct.

51.Install the bulkhead cover.

52.Install the under-cowl lower panel and cowl cover.

53.Install the windshield wiper arms.

54.Install the battery tray and battery, then secure the battery with its hold-down bracket.

55.Connect the battery terminals, and apply grease around the battery terminals.

56.Set the parking brake. Start the engine, and shift the transmission through all positions three times.

57.Check the shift lever operation, A/T gear position indicator operation, and shift cable adjustment.

58.Check and adjust the front wheel alignment.

59.Install the splash shield.

60..Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fan comes on). Turn off the engine, and check the ATF level

61.Enter the radio (and navigation) anti-theft code, then enter the radio presets, and set the clock.

62.Do the power window control unit reset procedure.

63.Perform the road test.