CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL BREATHER PLUG HOSE

    Tech Tips

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


    1. Install the No. 1 breather plug (CVT) to the breather plug hose.

    2. Install the breather plug hose with the No. 1 breather plug (CVT) to the continuously variable transaxle assembly.

  2. INSTALL WITH HEAD STRAIGHT SCREW PLUG

    Tech Tips

    Perform this procedure only when replacement of the with head straight screw plug is necessary.


    1. Install the with head straight screw plug to the continuously variable transaxle assembly with a new gasket.

      Torque:
      16.2 N*m  { 165 kgf*cm, 12 ft.*lbf }

  3. INSTALL WIRE HARNESS 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:
      12.5 N*m  { 127 kgf*cm, 9 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. B0042MXC11
      *1 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

    3. 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 }

  5. 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 }

  6. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. 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 }

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

    3. B0042OBC01
      *a 0 to 0.5 mm (0 to 0.0197 in.)

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

    4. 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

      Note


      • Drive the CVT oil pump type T oil seal in gradually, while visually checking that it is even.

      • 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.

      Tech Tips

      The CVT oil pump type T oil seal should be driven in between 0 to 0.5 mm (0 to 0.0197 in.) as measured from the side surface of the oil pump housing.

  9. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B00433XC02
      *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. B0043YVC03
      *a Key
      *b Matchmark

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

    3. B0041OGC02
      *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. B0043WIC02
      *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. B0043MSC02
      *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. B0042Y3C02
      *a Engine Surface
      *b Drive Plate Surface

      Using a vernier caliper and straightedge, measure dimension "A" between the transaxle contact surface of the engine assembly*a and the torque converter assembly contact surfaces of the drive plate*b.

    8. B00433QN02

      Using a vernier caliper and 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
      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. B0042IOC07
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece

      Apply clutch spline grease to the circumference 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. B0041S9C02
      *1 Knock Pin

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

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

      Torque:
      29.5 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 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 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. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR (for 1ZR-FAE)

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  12. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR (for 1ZR-FE)

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  13. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR (for 2ZR-FE)

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  14. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 1ZR-FAE)

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  15. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 1ZR-FE)

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  16. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 2ZR-FE)

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  17. INSTALL STARTER ASSEMBLY (for 1ZR-FAE)

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  18. INSTALL STARTER ASSEMBLY (for 1ZR-FE)

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  19. INSTALL STARTER ASSEMBLY (for 2ZR-FE)

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  20. CONNECT ENGINE WIRE


    1. Engage the 6 clamps.

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

    3. Connect the oil pressure sensor connector.

    4. Connect the park/neutral position switch assembly connector.

    5. Connect the transmission revolution sensor (NT) connector.

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

    7. Connect the transmission wire connector.

  21. INSTALL WATER BY-PASS HOSE


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

    2. Engage the water by-pass hose clamp.

  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (for 1ZR-FAE)

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  23. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (for 1ZR-FE)

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  24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (for 2ZR-FE)

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  25. REMOVE ENGINE HANGER (for 1ZR-FAE)

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  26. REMOVE ENGINE HANGER (for 1ZR-FE)

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  27. REMOVE ENGINE HANGER (for 2ZR-FE)

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  28. INSTALL WIRE HARNESS CLAMP BRACKET (for 1ZR-FAE)

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  29. INSTALL WIRE HARNESS CLAMP BRACKET (for 1ZR-FE)

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  30. INSTALL WIRE HARNESS CLAMP BRACKET (for 2ZR-FE)

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  31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  32. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH

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  33. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH

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  34. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


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

    2. B0041QEC29
      *1 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

    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.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      SST
      09213-58014   ( 91551-80840 )

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      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.

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

  35. INSTALL FLYWHEEL HOUSING UNDER COVER (for 1ZR-FAE)

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  36. INSTALL FLYWHEEL HOUSING UNDER COVER (for 1ZR-FE)

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  37. INSTALL FLYWHEEL HOUSING UNDER COVER (for 2ZR-FE)

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  38. RESET MEMORY

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