БЕССТУПЕНЧАТАЯ ТРАНСМИССИЯ В СБОРЕ УСТАНОВКА


  1. INSTALL TORQUE CONVERTER ASSEMBLY


    1. Clean the torque converter assembly set bolt holes.

    2. A01CF3BE01

      Using a vernier caliper and straightedge, measure dimension "A" between the transaxle contact surface of the engine*1 and the torque converter assembly contact surface of the drive plate*2. (#)

      Note

      Make sure to deduct the thickness of the straightedge.

    3. A01CC96E01
      Text in Illustration
      *1 Matchmark
      *2 Groove

      Turn the front oil pump drive gear so that the groove is at the top and put a matchmark on the housing.

    4. A01CEDUE02
      Text in Illustration
      *1 Key
      *2 Matchmark

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

    5. A01CAK6E01
      Text in Illustration
      *1 Matchmark

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

      Note

      Install the torque converter assembly horizontally to the input shaft.

    6. A01CF1QE01
      Text in Illustration
      *1 Matchmark
      *2 Oil Seal

      Rotate the torque converter assembly and mesh the splines of the stator shaft with the stator splines.

      Note


      • Do not damage the oil seal.

      • Install the torque converter assembly horizontally to the input shaft.

      Tech Tips

      Rotate the torque converter assembly approximately 180°.

    7. A01CF7CE01
      Text in Illustration
      *1 Matchmark
      *2 Oil Seal

      Rotate the torque converter assembly again, align the matchmark on the housing with the one on the torque converter assembly and fit 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.

      • Do not damage the oil seal.

      • Install the torque converter assembly horizontally to the input shaft.

    8. A01CE33E01

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

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

      Note

      Subtract the thickness of the straightedge from the measured value to gain dimension "B".

  2. INSTALL ENGINE MOUNTING BRACKET LH


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

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

  3. 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 }

  4. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. A01CC3XE02
      Text in Illustration
      *1 Torque Converter Assembly Centerpiece
      *2 Crankshaft

      Apply clutch spline grease to the circumference of the crankshaft contact surface with the torque converter assembly centerpiece.

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      About 1 g (0.0353 oz.)
    2. A01CF62E01

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

    3. Apply adhesive to the threads of a new bolt labeled D.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Maintain the engine and continuously variable transaxle assembly in a horizontal position, align the knock pins with each hole on the continuously variable transaxle assembly and install the continuously variable transaxle assembly with the 9 bolts shown in the illustration.

      Torque:
      for bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      for bolt B
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }
      for bolt C
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      for bolt D
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt length
      for bolt A
      55 mm (2.17 in.)
      for bolt B
      65 mm (2.56 in.)
      for bolt C
      32 mm (1.26 in.)
      for bolt D
      38 mm (1.50 in.)

      Tech Tips

      Bolt A and B: Install from transaxle side

      Bolt C and D: Install from engine side

      Note


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

      • Make sure that the torque converter assembly rotates.

      • Do not reuse bolt D.

      • Before applying adhesive 1324 to bolt D, remove any sealant from its installation hole in the continuously variable transaxle assembly.

      • After installing bolt D, leave the continuously variable transaxle assembly at least 1 hour.

  5. INSTALL OIL COOLER (w/o Air Cooled Transmission Oil Cooler)


    1. Install the oil cooler to the continuously variable transaxle assembly with the 3 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 8 ft.*lbf }

    2. Connect the 2 oil cooler hoses to the continuously variable transaxle assembly and engage the 2 clamps.

    3. Install the water by-pass hose and 2 oil cooler hoses to the oil cooler and engage the 3 clamps.

  6. INSTALL OIL COOLER (w/ Air Cooled Transmission Oil Cooler)


    1. Install the oil cooler to the continuously variable transaxle assembly with the 3 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 8 ft.*lbf }

    2. Connect the 2 water by-pass hoses to the oil cooler and engage the 2 clamps.

    3. Install the 2 oil cooler hoses to the oil cooler and continuously variable transaxle assembly and engage the 4 clamps.

  7. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A01CCMQE02
      Text in Illustration
      *1 Ground Cable

      Install the shift cable bracket and 2 wire harness clamp brackets to the continuously variable transaxle assembly with the 2 bolts.

      Torque:
      for bolt A
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for bolt B
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Install the ground cable to the wire harness clamp bracket with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  8. INSTALL ENGINE WIRE


    1. Install the 2 wire harness clamps and connect the oil pressure sensor connector to the continuously variable transaxle assembly.

    2. Install the 4 wire harness clamps and connect the 3 revolution sensor connectors, park/neutral position switch assembly connector and transmission wire connector to the continuously variable transaxle assembly.

  9. INSTALL STARTER ASSEMBLY (for 1.6 kW Type)


    1. A01CBGO

      Установите стартер и закрепите его 2 болтами.

      Torque:
      37 Н*м  { 377 кгс*см, 27 фунт-сила-футов }

    2. Подсоедините разъем стартера.

    3. Подсоедините зажим.

    4. Заверните гайку контакта и закройте ее колпачком.

      Torque:
      9,8 Н*м  { 100 кгс*см, 87 фунт-сила-дюймов }

  10. INSTALL STARTER ASSEMBLY (for 1.7 kW Type)


    1. A01CCR0

      Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    2. Connect the starter connector.

    3. Connect the clamp.

    4. Install the terminal nut, and cover the nut with the cap.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  11. INSTALL REAR ENGINE MOUNTING BRACKET


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

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

  12. INSTALL FRONT ENGINE MOUNTING BRACKET


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

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

  13. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR


    1. Временно установите подушку задней опоры двигателя на кронштейн опоры двигателя и закрепите ее стяжным болтом.

  14. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR


    1. Установите подушку передней опоры двигателя и предварительно закрепите ее стяжным болтом и гайкой.

  15. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A01CCEBE02

      Временно закрепите переднюю поперечину на передней подушке опоры двигателя с помощью болта A, а затем затяните болт B.

      Torque:
      95 Н*м  { 969 кгс*см, 70 фунт-сила-футов }

    2. Затяните болт А.

      Torque:
      95 Н*м  { 969 кгс*см, 70 фунт-сила-футов }

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tech Tips

    See the steps from "Install Engine Assembly with Transaxle" through "Check ABS Speed Sensor Signal" Click here.

  17. RESET MEMORY


    1. Perform Reset Memory (CVT initialization) when replacing the continuously variable transaxle assembly Click here.