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 BREATHER PLUG HOSE

    Tech Tips

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


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

    2. Install the 2 breather plugs to the breather plug hose.

    3. Install the breather plug hose to the transaxle housing sub-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 transaxle case with a new gasket.

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

  3. INSTALL OIL COOLER ELBOW SUB-ASSEMBLY


    1. Install a new gasket and oil cooler elbow sub-assembly to the transaxle case with the union bolt.

      Torque:
      22.6 N*m  { 230 kgf*cm, 17 ft.*lbf }

    2. Connect the outlet No. 1 oil cooler hose to the oil cooler elbow sub-assembly and slide the clip to secure it.

      B006NN9C01
      *1 Outlet No. 1 Oil Cooler Hose - -
      *a White Mark *b Up
      *c Left Side of the Vehicle *d 2 to 7 mm (0.0787 to 0.276 in.)

  4. INSTALL TUBE CONNECTOR


    1. Install a new O-ring to the tube connector.

    2. Install the tube connector to the transaxle case.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

    3. Connect the inlet No. 1 oil cooler hose to the tube connector and slide the clip to secure it.

      B006M3IC01
      *1 Outlet No. 1 Oil Cooler Hose - -
      *a White Mark *b Left Side of the Vehicle
      *c Front of the Vehicle *d 2 to 7 mm (0.0787 to 0.276 in.)

  5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


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

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

    2. Engage the No. 1 outlet oil cooler hose clamp.

  6. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 3 wire harness clamp brackets to the transaxle case with the 3 bolts.

      B006OSOC01
      *1 Wire Harness Clamp Bracket - -
      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  7. 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. B006P6IC01
      *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 0.0197 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 0.0197 in.) as measured from the side surface of the oil pump housing.

  8. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B006KKOC01
      *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 transaxle housing sub-assembly to indicate the position of the groove.

      Note


      • Place the matchmark on the transaxle housing sub-assembly to indicate the position of the wide groove.

      • The matchmark position must be correct to prevent damage.

    2. B006O8CC01
      *a Key
      *b Matchmark

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

    3. B006MJFC01
      *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.

    4. B006MQ2C01
      *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. B006O1JC01
      *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.

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

    7. B006KSAC01
      *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 and the torque converter assembly contact surfaces of the drive plate.

    8. B006OOCN02

      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.

  9. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    CAUTION:

    The continuously variable transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop or a part may fall.


    1. Using a transmission jack attachment, set the continuously variable transaxle assembly on a transmission jack.

      Note


      • Secure the continuously variable transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.

      • To prevent the transaxle oil (CVT) pan sub-assembly from deforming, do not place any attachments under the transaxle oil (CVT) pan sub-assembly.

      • Hold the engine assembly with a suitable adapter, such as a rope, during the operation.

    2. B006MTUC01
      *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)
    3. B006LA9C01
      *1 knock pin

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

    4. Install the continuously variable transaxle assembly to the engine assembly with the 9 bolts.

      Bolt Bolt Length Torque
      (A) 55 mm (2.17 in.) 64 N*m (653 kgf*cm, 47 ft.*lbf)
      (B) 32 mm (1.26 in.) 44 N*m (449 kgf*cm, 32 ft.*lbf)
      33 mm (1.30 in.) 43 N*m (438 kgf*cm, 32 ft.*lbf)
      (C) 45 mm (1.77 in.) 35 N*m (357 kgf*cm, 26 ft.*lbf)
      (D) 50 mm (1.97 in.) 46 N*m (469 kgf*cm, 34 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.

  10. INSTALL AUTOMATIC TRANSMISSION CASE COVER


    1. Install the automatic transmission case cover to the transaxle case with the 2 clips.

  11. CONNECT ENGINE WIRE


    1. B006R9YC02
      *a Oil Pressure Sensor Connector
      *b Transmission Revolution Sensor (NOUT) Connector

      Install the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    2. Engage the 2 clamps.

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

    4. Connect the oil pressure sensor connector.

    5. B006LQDC03
      *a Transmission Revolution Sensor (NIN) Connector
      *b Transmission Revolution Sensor (NT) Connector
      *c Transmission Wire Connector
      *d Park/Neutral Position Switch Assembly Connector
      *e Oil Pump with Motor Assembly Connector

      Engage the 3 clamps to connect the engine wire.

    6. Connect the oil pump with motor assembly connector.

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

    8. Connect the transmission wire connector.

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

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

    11. Install the bolt.

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

  12. INSTALL OIL COOLER

    Click here

  13. INSTALL ENGINE MOUNTING BRACKET LH


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

    2. B006MJ5C21
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 6 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper installation of the 6 bolts, apply adhesive to the 6 bolts and install them within 10 minutes of adhesive application.

    3. B006NAZC01

      Install the engine mounting bracket LH to the transaxle case with the 6 bolts.

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

      Note


      • Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (D) and (A).

      • Temporarily tighten the bolt (E), and then fully tighten the 2 bolts in the order of (F) and (E).

  14. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. B006LC0C01

      Install the front engine mounting bracket to the transaxle housing sub-assembly with the 3 bolts.

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

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 3 bolts in the order of (B), (C) and (A).

  15. INSTALL REAR ENGINE MOUNTING BRACKET


    1. B006M1EC01

      Install the rear engine mounting bracket to the Transaxle housing sub-assembly with the 3 bolts.

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

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 3 bolts in the order of (B), (C) and (A).

  16. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

    Click here

  17. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

    Click here

  18. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  19. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  20. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY LH

    Click here

  21. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  22. INSTALL REAR ENGINE MOUNTING INSULATOR

    Click here

  23. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Click here

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


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

    2. B006Q4IC01
      *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 drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

      Note

      First install the black colored drive plate and torque converter assembly setting bolt, and then the remaining 5 silver colored drive plate and torque converter assembly setting bolts.

  25. INSTALL FLYWHEEL HOUSING UNDER COVER

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  26. RESET MEMORY

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