CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL TRANSMISSION CASE PLUG ASSEMBLY


    1. A01VHXP

      Apply Toyota Genuine CVT Fluid TC to the O-rings on 2 new transmission case plugs.

  2. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 4 wire harness clamp brackets with the 5 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  3. INSTALL BREATHER PLUG HOSE


    1. Engage the clamp and install the breather plug hose to the wire harness clamp bracket.

  4. INSTALL ENGINE MOUNTING BRACKET LH


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

    2. A01VLEIE16
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Temporarily install the engine mounting bracket LH with the 4 bolts.

    4. A01VITZE02

      Tighten the 4 bolts in the order shown in the illustration.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  5. INSTALL ENGINE MOVING CONTROL ROD


    1. A01VFL1E06

      Temporarily install the engine moving control rod with the 3 bolts.

      Bolt Length
      Bolt Length
      A 25.0 mm (0.984 in.)
      B 33.5 mm (1.319 in.)
    2. A01VGJ4E02

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  6. INSTALL CVT OIL PUMP TYPE T OIL SEAL


    1. A01VKOOE10

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

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

    3. Clean the oil seal contact section of the SST and the area around it.

    4. Using the SST, drive the CVT oil pump type T oil seal in evenly, as far as the side surface of the oil pump housing.

      Standard oil seal drive in depth
      -0.2 to 0.2 mm
      SST
      09309-36010

      Note


      • Drive the oil seal in gradually, while visually checking the parallelism.

      • After the installation, confirm that the oil seal has been driven in as far as the side surface of the oil pump housing.

      • Wipe off any grease that has oozed out with your hand.

  7. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A01VHGQE04
      Text in Illustration
      *a Wide Groove
      *b Narrow Groove
      *c Matchmark

      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.

    2. A01VEMLE02
      Text in Illustration
      *a Key
      *b Matchmark

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

    3. A01VGY0E02
      Text in Illustration
      *1 CVT Oil Pump Type T Oil Seal
      *a Matchmark

      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.

    4. A01VHJ1E01
      Text in Illustration
      *1 CVT Oil Pump Type T Oil Seal
      *a Matchmark

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

      Note


      • Do not damage the oil seal.

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

    5. A01VFXWE02
      Text in Illustration
      *1 CVT Oil Pump Type T Oil Seal
      *a Matchmark

      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.

      Note


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

      • Do not damage the oil seal.

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

    6. Clean the torque converter assembly set bolt holes.

    7. A01VLJ2E02
      Text in Illustration
      *a CVT Installation Surface
      *b Torque Converter Assembly Installation Surface

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

    8. A01VL0ZE04

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

      Standard
      B=A+1 mm (0.0394 in.) or more

      Note


      • Make sure to deduct the thickness of the straightedge.

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

      • Do not include the thickness of the set block.

  8. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE


    1. Confirm that 2 knock pins are on the transaxle contact surface of the engine cylinder block before transaxle installation.

    2. A01VM7YE02
      Text in Illustration
      *1 Torque converter Assembly centerpiece
      *2 Crankshaft

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

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      About 1 g (0.0353 oz)
    3. A01VF8PE02
      Text in Illustration
      *1 Knock Pin

      While keeping the engine and continuously variable transaxle horizontal, align the knock pins with the holes in the continuously variable transaxle and install the 8 bolts shown in the illustration.

      Torque:
      for Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      for Bolt B
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note


      • Confirm that the 2 knock pins are installed to the transaxle contact surface of the engine cylinder block before installing the transaxle.

      • Do not forcibly pry on the continuously variable transaxle.

      • Check that the torque converter assembly rotates.

  9. TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Temporarily install the front suspension crossmember sub-assembly to the engine moving control rod.

      Tech Tips

      Perform final tightening after installing the engine assembly with transaxle to the vehicle Click here.

  10. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. A01VLEIE16
      Text in Illustration
      *1 Adhesive

      Apply a few drops of adhesive to 2 or 3 threads at the tips of the 6 torque converter assembly setting bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using SST to hold the crankshaft pulley in place.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    3. Turn the crankshaft to get the bolts position and install the 6 drive plate and torque converter assembly setting bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Tighten the black-colored bolt first, and then tighten the 5 silver-colored bolts.

  11. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  12. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  13. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  14. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


    1. Install the No. 1 transmission control cable bracket with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Engage the clamp and install the engine wire.

  15. INSTALL ENGINE WIRE


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

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. Attach the 2 wire harness clamps and connect the 2 revolution sensor connectors and transmission wire connector to the continuously variable transaxle.

    3. Connect the park/neutral position switch connector to the continuously variable transaxle.

    4. Attach the 4 wire harness clamps and connect the oil pressure sensor connector, revolution sensor connector to the continuously variable transaxle.

    5. w/ Stop and start system :


      1. Connect the oil pump with motor assembly connector.

  16. INSTALL WATER BY-PASS HOSE ASSEMBLY


    1. Engage the clamp and install the water bypass hoses.

    2. Install the water bypass hoses onto the oil cooler with the 2 hose clamps.

  17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  18. RESET MEMORY (CVT initialization)

    Note

    Perform reset memory (CVT initialization) when replacing the continuously variable transaxle Click here.