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


  1. INSTALL NO. 1 BREATHER PLUG

    Tech Tips

    Perform this procedure only when replacement of the breather plug hose is necessary.


    1. Install a new No. 1 breather plug to the breather plug hose.

  2. 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 }

  3. INSTALL WIRE HARNESS CLAMP BRACKET

    B0040QLE02
    Text in Illustration
    *1 Water By-pass Hose Clamp *2 Wire Harness Clamp Bracket
    *3 Water By-pass Hose Clamp Bracket - -

    1. Install the 4 wire harness clamp brackets and water by-pass hose clamp bracket to the continuously variable transaxle assembly with the 5 bolts.

      Torque:
      Bolt A
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }
      Bolt B
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

    2. Install the water by-pass hose clamp to the water by-pass hose clamp bracket.

  4. INSTALL ENGINE MOUNTING BRACKET LH


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

    2. B0040ONE48
      Text in Illustration
      *a Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper installation of the 4 bolts, apply adhesive to the 4 bolts and install them within 10 minutes of adhesive application.

    3. B0040MME02

      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 }

      Note

      Tightening order: Temporarily install bolt (A) → Tighten bolt (B) → Tighten bolt (C) → Tighten bolt (A)

  5. INSTALL REAR ENGINE MOUNTING BRACKET


    1. B0040LTE02

      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 }

      Note

      Tightening order: Temporarily install bolt (A) → Tighten bolt (B) → Tighten bolt (C) → Tighten bolt (A)

  6. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. B0040PUE03

      Install the front engine mounting bracket to the continuously variable transaxle assembly with the 4 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 (D) → Tighten bolt (A)

  7. 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 }

  8. 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 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.

    4. B0040KUE16
      Text in Illustration
      *a 0 to 0.5 mm (0 to 0.0196 in.)

      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.

      SST
      09309-36010
      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 to 0.5 mm (0 to 0.0196 in.) as measured from the side surface of the oil pump housing.

  9. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B0040HDE07
      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. B0040H3E03
      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. B0040LBE03
      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. B0040KBE04
      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. B0040O9E03
      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. B0040KPE03
      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.

    8. B0040NVE03

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

      Standard
      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.

  10. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. B0040IEE04
      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)
    2. B0040M3E03
      Text in Illustration
      *1 Knock Pin

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

    3. Install the continuously variable transaxle assembly to the engine assembly with the 7 bolts.

      Torque:
      30 N*m  { 301 kgf*cm, 22 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 installing 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

  11. CONNECT ENGINE WIRE


    1. B0040Q6

      Connect the transmission wire connector.

    2. Connect the transmission revolution sensor (NIN) connector.

    3. Attach the clamp.

    4. B0040HT

      Connect the park/neutral position switch assembly connector.

    5. Attach the clamp.

    6. B0040IGE03
      Text in Illustration
      *a Transmission Revolution Sensor (NOUT) Connector
      *b Oil Pressure Sensor Connector

      Connect the oil pressure sensor connector.

    7. Connect the transmission revolution sensor (NOUT) connector.

    8. Attach the 5 clamps.

  12. INSTALL GROUND CABLE


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

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

    2. Attach the clamp.

  13. CONNECT WATER BY-PASS HOSE


    1. Connect the water by-pass hose and slide the 2 clips to secure it.

      Note

      Fully insert the water by-pass hose to the 2nd rib on each transmission oil cooler pipe.

    2. Connect the water by-pass hose with the 2 clamps.

  14. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  17. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTINGBOLT


    1. Clean the threads of the 6 drive plate and torque converter assembly setting bolts.

    2. B0040GDE69
      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.

    3. 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
      09213-54015
      09330-00021

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

      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.

  18. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  19. RESET MEMORY

    Click here