CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL TRANSMISSION CASE PLUG ASSEMBLY

    Tech Tips

    After replacing the continuously variable transaxle assembly, perform the following procedure.


    1. A01VHM6

      Apply a light coat of Toyota Genuine CVT fluid FE to the 2 O-rings of 2 new transmission case plug assemblies.

  2. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 4 wire harness clamp brackets to the continuously variable transaxle assembly with the 5 bolts.

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

  3. INSTALL BREATHER PLUG HOSE


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

  4. INSTALL ENGINE MOUNTING BRACKET LH


    1. Clean and degrease the 4 bolts and installation holes in the engine mounting bracket LH.

    2. A01VFCBE19
      Text in Illustration
      *a 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

      Note

      To prevent contamination by foreign matter, install immediately after applying adhesive.

    3. A01VDLJE03
      Text in Illustration
      *a Temporarily Tighten

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

      Bolt Length
      Bolt Length
      A 25 mm (0.984 in.)
      B 33.5 mm (1.32 in.)
    2. A01VFL1E07
      Text in Illustration
      *a Temporarily Tighten

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

    3. A01VKOOE11
      Text in Illustration
      *a Drive in Depth

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

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

      SST
      09309-36010
      Standard oil seal drive in depth
      -0.2 to 0.2 mm (-0.00787 to 0.00787 in.)

      Note


      • Drive the CVT oil pump type T oil seal in gradually, while visually checking the parallelism.

      • After the 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.

  7. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A01VHGQE05
      Text in Illustration
      *a Matchmark
      *b Wide Groove
      *c Narrow Groove

      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.

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

    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 assembly.

      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.

    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 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.

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

    7. A01VLJ2E02
      Text in Illustration
      *a Engine Surface
      *b Drive Plate Surface

      Using a vernier caliper and a straightedge, measure 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.

    8. A01VL0ZE03

      Using a vernier caliper and a 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 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.

  8. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. A01VHB1E02
      Text in Illustration
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
      A01VL3H Clutch Spline Grease

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

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum grease amount
      Approximately 1 g (0.0353 oz.)
    2. A01VF8PE02
      Text in Illustration
      *1 Knock Pin

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

    3. Maintain the engine assembly and continuously variable transaxle assembly in a horizontal position, align the knock pins with each hole in the continuously variable transaxle assembly and install the continuously variable transaxle assembly to the engine assembly with the 8 bolts.

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

      Note


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

      • Do not forcibly pry on the continuously variable transaxle assembly.

      • When mounting the continuously variable transaxle assembly to the engine assembly, make sure to securely fit the 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 continuously variable transaxle assembly are in close contact with one another.

  9. TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


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

      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. Remove any adhesive remaining in the 6 drive plate and torque converter assembly setting bolts.

    2. A01VFCBE27
      Text in Illustration
      *a Adhesive

      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

      Note

      To prevent contamination by foreign matter, install immediately after applying adhesive.

    3. A01VK4ZE02

      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.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note


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

      • Do not start the engine for at least 1 hour after installing the drive plate and torque converter assembly setting bolts.

  11. INSTALL STARTER ASSEMBLY

    Click here

  12. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  13. 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.

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

    2. Engage the clamp to install the engine wire to the No. 1 transmission control cable bracket.

  14. INSTALL ENGINE WIRE


    1. Install the engine wire to the continuously variable transaxle assembly with the bolt.

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

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

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

    4. Engage the 4 clamps and connect the oil pressure sensor connector and revolution sensor connector to the continuously variable transaxle assembly.

    5. w/ Stop and Start System:


      1. Connect the oil pump with motor assembly connector to the continuously variable transaxle assembly.

  15. CONNECT WATER BY-PASS HOSE ASSEMBLY


    1. Engage the 2 clamps to install the water by-pass hose assembly to the continuously variable transaxle assembly.

    2. Connect the 2 water by-pass hoses to the transmission oil cooler and slide the 2 hose clamps to secure them.

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  17. RESET MEMORY (CVT initialization)

    Note

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