CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 TRANSAXLE CASE PLUG

    Tech Tips

    Perform this procedure only when replacement of the No. 2 transaxle case plug is necessary.


    1. A0054Z3

      Install the No. 2 transaxle case plug and a new gasket to the continuously variable transaxle assembly.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  2. INSTALL CVT OIL PUMP TYPE T OIL SEAL


    1. Ensure that there is no dirt or foreign matter on your hands, and then apply genuine TOYOTA MP grease No.2 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. B0040KUE01

      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.

      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.

      Tech Tips

      The oil seal should be driven in between 0 and 0.5mm (as measured from the side surface of the oil pump housing).

  3. INSTALL TORQUE CONVERTER ASSEMBLY


    1. Clean the torque converter set bolt holes.

    2. A005980E03

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

    3. A0058KYE05
      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. A00538NE13
      Text in Illustration
      *1 Key
      *2 Matchmark

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

    5. A0057L2E04
      Text in Illustration
      *1 Matchmark

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

      Note

      Install the torque converter horizontally to the input shaft.

    6. A0052SIE06
      Text in Illustration
      *1 Matchmark
      *2 Oil Seal

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

      Note


      • Do not damage the oil seal.

      • Install the torque converter horizontally to the input shaft.

      Tech Tips

      Rotate the torque converter approximately 180°.

    7. A0054EUE06
      Text in Illustration
      *1 Matchmark
      *2 Oil Seal

      Rotate the torque converter again, align the matchmark on the housing with the one on the torque converter and fit the key of the torque converter into the groove of the oil pump drive gear.

      Note


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

      • Do not damage the oil seal.

      • Install the torque converter horizontally to the input shaft.

    8. A00568NE02

      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".

  4. INSTALL WIRE HARNESS CLAMP BRACKET

    A005573

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

      Torque:
      13 N*m  { 131 kgf*cm, 8 ft.*lbf }

    2. Attach the water by-pass hose clamp to the wire harness clamp bracket.

  5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

    A0055R5

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

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

  6. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    A0053C7E03

    1. Apply clutch spline grease to the round of the crankshaft contact surface with the torque converter centerpiece.

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      About 1 g (0.0353 oz.)
      Text in Illustration
      *1 Torque Converter Centerpiece
      *2 Crankshaft
    2. A0058CCE03

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

    3. 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 7 bolts shown in the illustration.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }

      Tech Tips


      • Bolt A: Install from transaxle side

      • Bolt B: Install from engine side

      Note


      • Do not forcibly pry the continuously variable transaxle assembly.

      • Make sure that the torque converter rotates.

  7. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    B0040ON

    1. Apply a few drops of adhesive to 2 or 3 threads of the 6 torque converter setting bolt tips.

      Adhesive
      Toyota Genuine Adhesive 1324,
      Three Bond 1324 or equivalent
    2. A0054J7

      Turn the crankshaft to gain access to the installation locations of the 6 torque converter mounting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

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

      Note

      Install the black bolt first, and then the 5 silver bolts.

    3. Install the flywheel housing under cover.

  8. CONNECT ENGINE WIRE

    A00582YE03
    *1 for Front Side:
    *2 for Rear Side:

    1. for Front Side:

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

    2. for Rear Side:

      Attach the 5 wire harness clamps and connect the oil pressure sensor connector, revolution sensor connector and park/neutral position switch connector to the continuously variable transaxle.

  9. INSTALL GROUND CABLE

    A0052UX

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

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

  10. INSTALL REAR ENGINE MOUNTING BRACKET

    A0058OI

    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 }

    2. Attach the engine wire clamp to the rear engine mounting bracket.

  11. INSTALL FRONT ENGINE MOUNTING BRACKET

    A0055LO

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

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

  12. INSTALL ENGINE MOUNTING BRACKET LH

    A00547A

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

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

  13. INSTALL STARTER ASSEMBLY

    Click here

  14. INSTALL TRANSMISSION OIL COOLER ASSEMBLY

    A0057V4

    1. Coat 2 new O-rings with CVT fluid FE and install them to the transmission oil cooler.

    2. Install the transmission oil cooler together with the oil cooler hose assembly to the continuously variable transaxle with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  15. CONNECT WATER BY-PASS HOSE

    A00553XE02
    Text in Illustration
    *1 Green Paint Mark
    *2 Red Paint Mark

    1. Connect the 2 water by-pass hoses with the 2 hose clips.

      Note

      Make sure the paint marks and pinching portion of each clip are facing the direction shown in the illustration.

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine with transaxle Click here.

  17. RESET MEMORY

    Tech Tips

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