CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY(When Not Using the Engine Support Bridge) INSTALLATION

Info Added 2017-10-06

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 TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

    Tech Tips

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


    1. 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.

    2. Install the No. 1 breather plug (CVT) and No. 2 breather plug (CVT) to the breather plug hose.

    3. Install the transmission breather hose sub-assembly to the continuously variable transaxle assembly.

  2. INSTALL STRAIGHT SCREW PLUG

    Tech Tips

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


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

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

  3. INSTALL NO. 1 HEATER BRACKET SUB-ASSEMBLY


    1. Install the No. 1 heater bracket sub-assembly to the continuously variable transaxle assembly with the bolt.

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

    2. Install the clamp to the No. 1 heater bracket sub-assembly.

    3. Install the No. 1 breather plug (CVT) to the clamp.

  4. 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 }

  5. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A005P8R

      Install the 4 wire harness clamp brackets to the continuously variable transaxle assembly with the 4 bolts.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

  6. INSTALL NO. 2 ENGINE MOVING CONTROL ROD


    1. A005Q6TC01
      *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 }

  7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the front suspension crossmember sub-assembly to the No. 2 engine moving control rod with the bolt.

      Torque:
      170 N*m  { 1734 kgf*cm, 125 ft.*lbf }

  8. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

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  9. INSTALL TRANSFER ASSEMBLY

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  10. 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 by hand.

      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. A005PY5C01
      *a Depth

      Using SST and a hammer, 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.

  11. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A005OX0C02
      *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 to indicate the position of the groove.

      Note


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

      • The matchmark position must be correct to prevent damage.

    2. A005P5IC03
      *a Key
      *b Matchmark

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

    3. A005QF8C02
      *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. A005OWRC02
      *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. A005POJC02
      *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 front 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. A005PF5C02
      *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*a and the torque converter assembly contact surfaces of the drive plate*b.

    8. A005PDTN02

      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.

  12. INSTALL ENGINE ASSEMBLY


    1. A005OT1C02
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
      B00495X Clutch Spline Grease

      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. A005OVOC02
      *1 Knock Pin

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

    3. Install the engine assembly to the continuously variable transaxle 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

  13. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET


    1. A005OO1C01
      *a Temporarily Tighten

      Install the transverse engine engine mounting bracket to the continuously variable transaxle assembly with the 3 bolts in the order shown in the illustration.

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

  14. INSTALL ENGINE MOUNTING STAY LH


    1. A005P8SC01
      *a Temporarily Tighten

      Install the engine mounting stay LH to the continuously variable transaxle assembly and transverse engine engine mounting bracket with the 2 bolts in the order shown in the illustration.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  15. INSTALL FLYWHEEL HOUSING SIDE COVER

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  16. INSTALL STARTER ASSEMBLY (for Valeo Made Cold Area Specification Vehicles)

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  17. INSTALL STARTER ASSEMBLY (for Valeo Made except Cold Area Specification Vehicles)

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  18. INSTALL STARTER ASSEMBLY (for Denso Made without Stop and Start System)

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  19. CONNECT WATER HOSE


    1. Engage the 2 clamps to install the water hose to the continuously variable transaxle assembly.

    2. Connect the water hose to the transmission oil cooler and slide the 2 hose clips to secure them.

  20. CONNECT ENGINE WIRE


    1. Engage the 7 clamps to connect the engine wire to the continuously variable transaxle assembly.

      A005QB1C02
      *1 Park/Neutral Position Switch Connector *2 Transmission Wire Connector
      *3 Transmission Revolution Sensor (NIN) Connector *4 Transmission Revolution Sensor (NOUT) Connector
      *5 Oil Pressure Sensor Connector - -

    2. Connect the oil pressure sensor connector.

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

    4. Connect the park/neutral position switch connector.

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

    6. Connect the transmission wire connector.

    7. Connect the engine wire to the continuously variable transaxle assembly with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    8. A005P4C

      Engage the 3 clamps to connect the engine wire to the front suspension crossmember sub-assembly.

  21. REMOVE ENGINE HANGER

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  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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  23. 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. A005Q31C01
      *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:
      28 N*m  { 286 kgf*cm, 21 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.

  24. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover to the stiffening crankcase assembly.

  25. RESET MEMORY

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