CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY(When Using the Engine Support Bridge)

INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

Tech Tips

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

Apply Toyota Genuine CVT fluid FE to a new O-ring, and install it to the No. 2 breather plug (CVT).

Note

Be careful not to damage or twist the O-ring.
Install the No. 1 breather plug (CVT) and No. 2 breather plug (CVT) to the breather plug hose.
Install the transmission breather hose sub-assembly to the continuously variable transaxle assembly.

INSTALL STRAIGHT SCREW PLUG

Tech Tips

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

Install a new gasket and the straight screw plug to the continuously variable transaxle assembly.

Torque:

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

INSTALL AUTOMATIC TRANSMISSION CASE COVER

Install the automatic transmission case cover to the continuously variable transaxle assembly with the 2 clips.

INSTALL OIL COOLER ELBOW SUB-ASSEMBLY

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

Torque:

22.6 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.
Install the No. 2 transmission oil cooler hose to the oil cooler elbow sub-assembly and slide the clip to secure it.

INSTALL TUBE CONNECTOR

Install a new O-ring to the tube connector.
Install the tube connector to the continuously variable transaxle assembly.

Torque:

27 N*m { 275 kgf*cm, 20 ft.*lbf }
Note
- Make sure to insert the painted end (white) of the No. 1 transmission oil cooler hose up to the spool fitting of the tube connector so that the marking is facing the front of the vehicle.
- Make sure to clean and degrease the insertion part of the No. 1 transmission oil cooler hose of the tube connector.
Install the No. 1 transmission oil cooler hose to the tube connector and slide the clip to secure it.

INSTALL WIRE HARNESS CLAMP BRACKET

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

Install the 3 wire harness clamp brackets to the continuously variable transaxle assembly with the 3 bolts.

Torque:: 8.0 N*m { 82 kgf*cm, 71 in.*lbf }

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 TRANSMISSION CONTROL CABLE SUPPORT

Install the transmission control cable support to the continuously variable transaxle assembly with the 2 bolts.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }

INSTALL CVT OIL PUMP TYPE T OIL SEAL

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.
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.
Clean the CVT oil pump type T oil seal contact surface of SST and the area around it.

SST

09309-36010
*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.

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.

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

INSTALL TORQUE CONVERTER ASSEMBLY

*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.
*a Key

*b Matchmark

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

SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

Using a transmission jack, support the continuously variable transaxle assembly.
Note
- Adjust the attachment of the transmission jack to securely fix the continuously variable transaxle assembly to the transmission jack.
- To prevent the transaxle oil (CVT) pan sub-assembly from deforming, do not place any attachments under the transaxle oil (CVT) pan sub-assembly of the continuously variable transaxle assembly.
- Using a lashing belt or a rope, fix the continuously variable transaxle assembly to the transmission jack.

INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

*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

Clutch spline grease
Toyota Genuine Clutch Spline Grease or equivalent

Maximum grease amount
Approximately 1 g (0.0353 oz.)

INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

*a Temporarily Tighten

Install the transverse engine engine mounting bracket with the 5 new bolts.

Torque:

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

INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR

*a Temporarily Tighten

Temporarily install the transverse engine engine mounting insulator to the vehicle body with the nut and 4 bolts.
Fully tighten the nut and 4 bolts in the order shown in the illustration.

Torque:

42 N*m { 428 kgf*cm, 31 ft.*lbf }
Install the transverse engine engine mounting insulator to the transverse engine engine mounting bracket with the bolt and nut.

Torque:

44 N*m { 449 kgf*cm, 32 ft.*lbf }

Note

Turn the bolt while holding the nut.

INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

INSTALL FLYWHEEL HOUSING UNDER COVER

Install the flywheel housing under cover.

INSTALL FLYWHEEL HOUSING SIDE COVER

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INSTALL STARTER ASSEMBLY

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INSTALL NO. 2 ENGINE MOVING CONTROL ROD

*a Temporarily Tighten

Install the No. 2 engine moving control rod to the continuously variable transaxle assembly with the 4 bolts in the order shown in the illustration.

Torque:

44 N*m { 449 kgf*cm, 32 ft.*lbf }

INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

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REMOVE ENGINE SUPPORT BRIDGE

Remove SST from the vehicle body.

Note

Prevent SST from contacting the vehicle body or windshield glass.
Install the neck from the windshield washer jar assembly with the clip.

REMOVE ENGINE HANGER

Remove the 2 bolts and No. 2 engine hanger from the cylinder head.
Remove the 2 bolts and No. 1 engine hanger from the cylinder head.
Install the wire harness clamp bracket with the bolt.

Torque:

39 N*m { 398 kgf*cm, 29 ft.*lbf }
Connect the air fuel ratio sensor connector.
Engage the 5 clamps.

INSTALL FRONT DRIVE SHAFT ASSEMBLIES

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INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

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INSTALL FRONT FLOOR CENTER BRACE

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INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

INSTALL COLUMN HOLE COVER SILENCER SHEET

Click here

INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

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 }
Connect the clamp to the No. 1 transmission control cable bracket.

CONNECT ENGINE WIRE

Engage the 5 clamps to connect the engine wire to the continuously variable transaxle assembly.

*1	Park/Neutral Position Switch Connector	*2	Transmission Wire Connector
*3	Transmission Revolution Sensor (NIN) Connector	*4	Transmission Revolution Sensor (NOUT) Connector
*5	Transmission Revolution Sensor (NT) Connector	*6	Oil Pressure Sensor Connector

Connect the engine wire to the continuously variable transaxle assembly with the 3 bolts and nut.

Torque:

Bolt (A)

8.5 N*m { 87 kgf*cm, 75 in.*lbf }

Bolt (B)

8.0 N*m { 82 kgf*cm, 71 in.*lbf }

Nut

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Connect the oil pressure sensor connector.
Connect the transmission revolution sensor (NOUT) connector.
Connect the transmission revolution sensor (NIN) connector.
Connect the transmission revolution sensor (NT) connector.
Connect the transmission wire connector.
Connect the park/neutral position switch connector.

CONNECT NO. 3 WATER BY-PASS HOSE

Connect the No. 3 water by-pass hose to the oil cooler, and slide the clip to secure it.
Note
- Align each paint mark on the No. 3 water by-pass hose with each one on the oil cooler.
- Fully insert the No. 3 water by-pass hose to the 2nd rib on each oil cooler pipe.

CONNECT NO. 5 WATER BY-PASS HOSE

Connect the No. 5 water by-pass hose to the 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 oil cooler.
- Fully insert the No. 5 water by-pass hose to the 2nd rib on each oil cooler pipe.

CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

Install the transmission control cable assembly to the transmission control cable support with the nut.

Torque:

5.0 N*m { 51 kgf*cm, 44 in.*lbf }
*a P Position

*b N Position

Turn the control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.
Install the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
Connect the transmission control cable assembly to the control shaft lever with the nut.

Torque:

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

INSTALL BATTERY CLAMP SUB-ASSEMBLY

Install the air battery clamp sub-assembly to the vehicle with the 3 bolts.

Torque:

15.4 N*m { 157 kgf*cm, 11 ft.*lbf }
Engage the clamp to connect the engine wire to the battery clamp sub-assembly.
Connect the engine wire to the battery clamp sub-assembly with the bolt and nut.

Torque:

7.0 N*m { 71 kgf*cm, 62 in.*lbf }