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

INSTALL AUTOMATIC TRANSMISSION CASE COVER
1. Install the automatic transmission case cover to the continuously variable transaxle assembly with the 2 clips.

INSTALL BREATHER HOSE SUB-ASSEMBLY

Tech Tips

Perform this procedure only when replacement of the breather hose sub-assembly is necessary.

Note

When replacing the continuously variable transaxle assembly, be sure to install the breather hose sub-assembly.

Text in Illustration
*1	Breather Plug
*2	O-ring
*3	Breather Hose

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

Install a new breather plug to the breather hose.
Install the breather hose sub-assembly to the continuously variable transaxle assembly.

INSTALL TRANSMISSION OIL FILLER TUBE STRAIGHT SCREW PLUG

Tech Tips

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.
  
  Torque:
  
  16.2 N*m { 165 kgf*cm, 12 ft.*lbf }
INSTALL OIL COOLER ELBOW SUB-ASSEMBLY
1. Install a new gasket and oil cooler elbow sub-assembly to the continuously variable transaxle assembly with the union bolt.
  
  Torque:
  
  23 N*m { 230 kgf*cm, 17 ft.*lbf }
  Note
  - Make sure to insert the painted end (white) of the No. 2 transmission oil cooler hose up to the spool fitting of the oil cooler elbow sub-assembly so that the marking is facing the front of the vehicle.
  - Make sure to clean and degrease the insertion part of the No. 2 transmission oil cooler hose of the oil cooler elbow sub-assembly.
2. Install the No. 2 transmission oil cooler hose to the oil cooler elbow sub-assembly and slide the clip to secure it.
INSTALL OIL COOLER TUBE UNION
1. Install a new O-ring to the oil cooler tube union.
2. Install the oil cooler tube union to the continuously variable transaxle assembly.
  
  Torque:
  
  27 N*m { 275 kgf*cm, 20 ft.*lbf }
3. Install the No. 1 transmission oil cooler hose to the oil cooler tube union and slide the clip to secure it.

INSTALL WIRE HARNESS CLAMP BRACKET

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

Torque:: 8.4 N*m { 85 kgf*cm, 74 in.*lbf }

Text in Illustration
*1	Wire Harness Clamp Bracket	*2	Water By-pass Hose Clamp
*3	Water Hose Clamp Bracket	-	-

Install the water by-pass hose clamp to the water hose clamp bracket.
Install the water hose clamp bracket to the continuously variable transaxle assembly with the bolt.

Torque:

10 N*m { 102 kgf*cm, 7 ft.*lbf }

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 the No. 1 transmission control cable bracket.
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 oil pump 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.
  
  SST
  
  09309-36010
4. Text in Illustration
  
  *a 0 to 0.5 mm
  
  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.
  
  Standard Depth
  
  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.
  Tech Tips
  
  The CVT oil pump type T oil seal should be driven in between 0 and 0.5 mm (0 and 0.0196 in.) as measured from the side surface of the oil pump housing.

Text in Illustration
*a	0 to 0.5 mm

Standard Depth
0 to 0.5 mm (0 to 0.0196 in.)

INSTALL TORQUE CONVERTER ASSEMBLY

Text in Illustration

*a Matchmark

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

Note

Align the matchmark with the wide groove of the transaxle housing.
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.

Text in Illustration
*a	Matchmark

Text in Illustration
*a	Key
*b	Matchmark

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

Align the matchmark on the transaxle 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.

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 type T oil seal.

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 transaxle housing and insert the key of the torque converter assembly into the groove of the oil pump drive gear.

Note

Install the torque converter assembly to the input shaft while keeping it horizontal.
Do not push the torque converter assembly excessively when rotating it.
Do not damage the CVT oil pump type T oil seal.

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

Text in Illustration
*a	Engine Assembly Surface
*b	Drive Plate Surface

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.

Using a vernier caliper and straightedge, measure the dimension (B) shown in the illustration and check that the dimension (B) is more than the 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.

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

INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

Text in Illustration
*1	Crankshaft
*a	Torque Converter Assembly Centerpiece

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)

Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.
Install the continuously variable transaxle assembly to the engine assembly with the 8 bolts.

Torque:

Bolt (A)

38 N*m { 387 kgf*cm, 28 ft.*lbf }

Bolt (B)

40 N*m { 408 kgf*cm, 30 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 mounting 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.
Tech Tips
- Bolt (A): Install from continuously variable transaxle assembly side
- Bolt (B): Install from engine assembly side

INSTALL ENGINE MOUNTING BRACKET LH
1. Clean and degrease the bolt holes of the continuously variable transaxle assembly.
2. Install the engine mounting bracket LH and engine mounting stay LH with the 6 new bolts.
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
  
  Note
  
  Tightening order: Tighten bolt (A), (B), (C), (D) → Tighten bolt (E) → Tighten bolt (F)
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 }
  
  Note
  
  Tightening order: Temporarily install bolt (A) →Tighten bolt (B) → Tighten bolt (C) → Tighten bolt (A)
INSTALL REAR ENGINE MOUNTING BRACKET
1. Install the rear engine mounting bracket to the continuously variable transaxle assembly with the 3 bolts.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
  
  Tech Tips
  
  Tightening order: Temporarily install bolt (A) →Tighten bolt (B) → Tighten bolt (C) → Tighten bolt (A)
INSTALL STARTER ASSEMBLY

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CONNECT BREATHER PLUG HOSE
1. Connect the breather plug hose to the clamp.
  
  Note
  
  When installing a new continuously variable transaxle assembly, remove the double clamp attached to the breather hose.
CONNECT ENGINE WIRE
1. Connect the 2 connectors.
2. Attach the 3 clamps.
3. Connect the engine wire with the bolt.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }
4. Attach the 2 clamps to install the engine wire.
5. Connect the ground cable with the bolt.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }
6. Connect the 4 connectors.
CONNECT NO. 6 WATER BY-PASS HOSE
1. Connect the No. 6 water by-pass hose to the transmission oil cooler, and slide the clip to secure it.
  Note
  - Align each paint mark on the No. 6 water by-pass hose with each one on the transmission oil cooler.
  - Fully insert the No. 6 water by-pass hose to the 2nd rib on each transmission oil cooler pipe.
CONNECT NO. 5 WATER BY-PASS HOSE
1. Connect the No. 5 water by-pass hose to the transmission oil cooler, and slide the clip to secure it.
  Note
  - Align each paint mark on the No. 5 water by-pass hose with each one on the transmission oil cooler.
  - Fully insert the No. 5 water by-pass hose to the 2nd rib on each transmission oil cooler pipe.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT
1. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-54015
  
  09330-00021
  
  Tech Tips
  
  Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)
2. Clean the threads of the 6 drive plate and torque converter assembly setting bolts.
3. 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
  
  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.
4. 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.
  
  Torque:
  
  41 N*m { 418 kgf*cm, 30 ft.*lbf }
  
  Note
  
  First install the black-colored bolt, and then the remaining 5 silver-colored bolts.
INSTALL FLYWHEEL HOUSING SIDE COVER
1. Install the flywheel housing under cover.
RESET MEMORY

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