CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with continuously variable transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE

  1. INSPECT BREATHER PLUG HOSE

    Tip:

    Perform this procedure only when replacement of the breather plug hose is necessary.

    1. C322520E03

      Install a new O-ring to a new breather plug.

      Table 1. Text in Illustration

      *1

      No. 1 Breather Plug

      *2

      No. 2 Breather Plug

      *3

      O-ring

      *4

      Breather Plug Hose

    2. Install the No. 2 breather plug to the breather plug hose.

    3. Install the No. 1 breather plug to the breather plug hose.

    4. Install the breather plug hose to the continuously variable transaxle assembly.

  2. INSTALL TRANSMISSION OIL FILLER TUBE STRAIGHT SCREW PLUG

    Tip:

    Perform this procedure only when replacement of the transmission oil filler tube straight screw plug is necessary.

    1. Install a new gasket and the transmission oil filler tube straight screw plug to the continuously variable transaxle assembly.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  3. INSTALL WIRE HARNESS CLAMP BRACKET

    C289745E02
    Table 2. Text in Illustration

    *1

    Water By-pass Hose Clamp

    *2

    Wire Harness Clamp Bracket

    *3

    Water By-pass Hose Clamp Bracket

    -

    -

    1. Install the 4 wire harness clamp brackets and water by-pass hose clamp bracket to the continuously variable transaxle assembly with the 5 bolts.

      19 N*m

      189 kgf*cm

      14 ft.*lbf

    2. Install the water by-pass hose clamp to the water by-pass hose clamp bracket.

  4. INSTALL ENGINE MOUNTING BRACKET LH

    1. Clean the bolts and the installation holes in the engine mounting bracket LH.

    2. P000601E43

      Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Table 3. Text in Illustration

      *a

      Adhesive
      Note:

      In order to ensure proper installation of the 4 bolts, apply adhesive to the 4 bolts and install them within 10 minutes of adhesive application.

    3. Install the engine mounting bracket LH to the continuously variable transaxle assembly with the 3 bolts.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

  5. INSTALL REAR ENGINE MOUNTING BRACKET

    1. Install the rear engine mounting bracket to the continuously variable transaxle assembly with the 3 bolts.

      45 N*m

      459 kgf*cm

      33 ft.*lbf

  6. INSTALL FRONT ENGINE MOUNTING BRACKET

    1. Install the front engine mounting bracket to the continuously variable transaxle assembly with the 4 bolts.

      45 N*m

      459 kgf*cm

      33 ft.*lbf

  7. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

    1. Install the No. 1 transmission control cable bracket to the continuously variable transaxle assembly with the 2 bolts.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  8. INSTALL CVT OIL PUMP TYPE T OIL SEAL

    1. Ensure that there is no dirt or foreign matter on your hands, and then apply MP grease to the entire periphery of the lip of a new CVT oil pump type T oil seal.

    2. Temporarily install the CVT oil pump type T oil seal by pressing it to the installation surface of the oil pump housing manually.

      Note:

      Be sure to install the CVT type T oil seal in the correct direction.

    3. Clean the CVT oil pump type T oil seal contact surface of SST and the area around it.

    4. C208789E12

      Using SST, drive the CVT oil pump type T oil seal in evenly, until it is even with the side surface of the oil pump housing.

      09309-36010

      Standard depth

      0 to 0.5 mm (0 to 0.0196 in.)

      Table 4. Text in Illustration

      *a

      0 to 0.5 mm (0 to 0.0196 in.)
      Note:

      • Drive the CVT oil pump type T oil seal in gradually, while visually checking that it is even.

      • After installation, confirm that the CVT oil pump type T oil seal has been driven in until it is even with the side surface of the oil pump housing.

      • Wipe any extra grease off with your hand.

      Tip:

      The CVT oil pump type T oil seal should be driven in between 0 to 0.5 mm (0 to 0.0196 in.) as measured from the side surface of the oil pump housing.

  9. INSTALL TORQUE CONVERTER ASSEMBLY

    1. C235921E06

      Turn the front oil pump drive gear so that the groove is at the top and place a matchmark on the housing to indicate the position of the groove.

      Note:

      • Place the matchmark on the housing to indicate the position of the wide groove.

      • The matchmark position must be correct to prevent damage.

      Table 5. Text in Illustration

      *a

      Matchmark

      *b

      Wide Groove

      *c

      Narrow Groove
    2. C289748E02

      Place a matchmark on the torque converter assembly so that the position of its key is clearly indicated.

      Table 6. Text in Illustration

      *a

      Key

      *b

      Matchmark
    3. C292498E02

      Align the matchmark on the housing with the one on the torque converter assembly and engage the splines of the input shaft with the turbine runner splines.

      Note:

      • Install the torque converter assembly to the input shaft while keeping it horizontal.

      • Do not damage the CVT oil pump type T oil seal.

      Table 7. Text in Illustration

      *1

      CVT Oil Pump Type T Oil Seal

      *a

      Matchmark
    4. C292499E03

      Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly.

      Note:

      Install the torque converter assembly to the input shaft while keeping it horizontal.

      Table 8. Text in Illustration

      *1

      CVT Oil Pump Type T Oil Seal

      *a

      Matchmark
    5. C292500E02

      Rotate the torque converter assembly approximately 180° again, align the matchmark on the torque converter assembly with the one on the housing and insert the key of the torque converter assembly into the groove of the oil pump drive gear.

      Note:

      • Do not push the torque converter assembly excessively when rotating it.

      • Install the torque converter assembly to the input shaft while keeping it horizontal.

      • Do not damage the CVT oil pump type T oil seal.

      Table 9. Text in Illustration

      *1

      CVT Oil Pump Type T Oil Seal

      *a

      Matchmark

    6. Clean the drive plate and torque converter assembly setting bolt holes.

    7. C273897E02

      Using a vernier caliper and straightedge, measure the dimension (A) between the continuously variable transaxle assembly contact surface of the engine assembly*a and the torque converter assembly contact surfaces of the drive plate*b.

      Table 10. Text in Illustration

      *a

      Engine Assembly Surface

      *b

      Drive Plate Surface
    8. C292501E02

      Using a vernier caliper and straightedge, measure the dimension (B) shown in the illustration and check that dimension (B) is more than dimension (A), which was measured in the previous step.

      Standard

      A + 1 mm (0.0394 in.) or more

      Note:

      • Make sure to deduct the thickness of the straightedge.

      • If the continuously variable transaxle assembly is installed to the engine assembly with the torque converter assembly not sufficiently inserted, the torque converter assembly may be damaged.

      • Do not include the thickness of the set block.

  10. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    1. C292502E03

      Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

      Clutch spline grease

      Toyota Genuine Clutch Spline Grease or equivalent

      Maximum Grease Amount Approximately 1 g (0.0353 oz)

      Table 11. Text in Illustration

      *1

      Crankshaft

      *a

      Torque Converter Assembly Centerpiece
    2. C274303E02

      Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.

      Table 12. Text in Illustration

      *1

      Knock Pin

    3. Install the continuously variable transaxle assembly to the engine assembly with the 7 bolts.

      30 N*m

      301 kgf*cm

      22 ft.*lbf

      Note:

      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.

      • Do not use excess force when installing the continuously variable transaxle assembly.

      • When installing the continuously variable transaxle assembly to the engine assembly, make sure to securely fit the 2 knock pins into the knock holes.

      • Check that the torque converter assembly rotates.

      • When tightening the bolts, be sure that the mating surfaces of the engine assembly and the continuously variable transaxle assembly are in close contact with one another.

      Tip:

      • Bolt (A): Install from continuously variable transaxle assembly side

      • Bolt (B): Install from engine assembly side

  11. CONNECT ENGINE WIRE

    1. C289741

      Connect the transmission wire connector.

    2. Connect the transmission revolution sensor (NIN) connector.

    3. Attach the clamp.

    4. C289740

      Connect the park/neutral position switch assembly connector.

    5. Attach the clamp.

    6. C322510E02

      Connect the oil pressure sensor connector.

      Table 13. Text in Illustration

      *a

      Transmission Revolution Sensor (NOUT) Connector

      *b

      Oil Pressure Sensor Connector

    7. Connect the transmission revolution sensor (NOUT) connector.

    8. Attach the 5 clamps.

  12. INSTALL GROUND CABLE

    1. Install the ground cable to the continuously variable transaxle with the bolt.

      13 N*m

      130 kgf*cm

      9 ft.*lbf

    2. Attach the clamp.

  13. CONNECT WATER BY-PASS HOSE

    1. Connect the water by-pass hose and slide the 2 clips to secure it.

      Note:

      Fully insert the water by-pass hose to the 2nd rib on each oil cooler pipe.

    2. Connect the water by-pass hose with the 2 clamps.

  14. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    (Click here)

  17. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTINGBOLT

    1. Clean the threads of the 6 drive plate and torque converter assembly setting bolts.

    2. A057108E63

      Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter assembly setting bolts.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Table 14. Text in Illustration

      *a

      Adhesive
      Note:

      In order to ensure proper installation of the 6 drive plate and torque converter assembly setting bolts, apply adhesive to the 6 drive plate and torque converter assembly setting bolts and install them within 10 minutes of adhesive application.

    3. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each bolt while holding the crankshaft pulley with SST.

      09213-54015

      09330-00021

      Tip:

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

      28 N*m

      286 kgf*cm

      21 ft.*lbf

      Note:

      First install the black-colored bolt, and then the remaining 5 silver-colored bolts.

  18. INSTALL FLYWHEEL HOUSING UNDER COVER

    1. Install the flywheel housing under cover.

  19. RESET MEMORY

    (Click here)