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

Info Added 2017-10-06

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the continuously variable transaxle assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedure Effect/Inoperative when not Performed Link
Disconnect cable from negative battery terminal Memorize steering angle neutral point

  • Lane departure alert system (w/ Steering Control)

  • Simple intelligent parking assist system*1

  • Toyota parking assist-sensor system (w/ Simple Intelligent Parking Assist System)*1

  • Pre-collision system

Click here

Initialize back door lock Power door lock control system

Click here


  • Air leaks from intake system

  • Gas leaks from exhaust system

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here

Replacement of CVT fluid ATF thermal degradation estimate reset The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

Click here

Replacement of continuously variable transaxle assembly

Perform the following procedures in the order shown:


  1. Reset memory

  2. Deceleration sensor zero point calibration

  3. CVT oil pressure calibration

 Deterioration of fuel efficiency

Click here

Front wheel alignment adjustment

Perform the following procedures in the order shown:


  1. Clear zero point calibration data and store system information

  2. Perform yaw rate and acceleration sensor zero point calibration and store system information

  • VSC disabled or malfunctions

  • Slip indicator light illuminates

  • ABS warning light illuminates

Click here

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)

 Initialize No. 1 headlight ECU sub-assembly LH Automatic headlight beam level control system

Click here


CAUTION:


  • A005PAKC01
    *a Heavy object exceeding the capacity of the transmission jack

    Because the continuously variable transaxle assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the transmission jack could drop and components could fall down.


  • A005OO6

    When the engine is hot, do not touch high-temperature areas such as the engine or exhaust pipe.

  • Touching high-temperature areas such as the engine and exhaust pipe could result in burns.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Click here

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  4. REMOVE FRONT WHEELS

    Click here

  5. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  6. REMOVE REAR ENGINE UNDER COVER RH

    Click here

  7. REMOVE REAR ENGINE UNDER COVER LH

    Click here

  8. REMOVE FRONT FLOOR COVER LH

    Click here

  9. REMOVE FRONT FLOOR COVER RH

    Click here

  10. DRAIN ENGINE COOLANT

    Click here

  11. DRAIN COOLANT (for Intercooler)

    Click here

  12. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  13. REMOVE WINDSHIELD WIPER MOTOR AND LINK

    Click here

  14. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  15. REMOVE WATER GUARD PLATE LH

    Click here

  16. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  17. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  18. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  19. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  20. REMOVE BATTERY

    Click here

  21. REMOVE RADIATOR COVER

    Click here

  22. REMOVE NO. 1 AIR CLEANER INLET

    Click here

  23. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  25. REMOVE ECM

    Click here

  26. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A005PE2

      Remove the bolt and nut to separate the engine wire from the battery clamp sub-assembly.

    2. A005PEM

      Disengage the clamp to separate the engine wire from the battery clamp sub-assembly.

    3. Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

  27. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  28. DISCONNECT ENGINE WIRE


    1. Disconnect the transmission wire connector.

      A005QB1C03
      *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. Disconnect the transmission revolution sensor (NIN) connector.

    3. Disconnect the park/neutral position switch connector.

    4. Disconnect the transmission revolution sensor (NOUT) connector.

    5. Disconnect the oil pressure sensor connector.

    6. Disengage the 7 clamps to disconnect the engine wire from the continuously variable transaxle assembly.

    7. Remove the bolt to disconnect the engine wire from the continuously variable transaxle assembly.

  29. DISCONNECT WATER HOSE


    1. A005OX7

      Slide the 2 hose clips and disconnect the water hoses from the transmission oil cooler.

    2. Disengage the 2 clamps to separate the water hose from the continuously variable transaxle assembly.

  30. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET


    1. A005PWS

      Remove the 2 bolts and No. 1 transmission control cable bracket from the continuously variable transaxle assembly.

  31. SECURE STEERING WHEEL ASSEMBLY

    Click here

  32. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  33. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  34. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  35. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  36. REMOVE NO. 2 CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  38. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  39. REMOVE FRONT DRIVE SHAFT ASSEMBLIES (for TMC Made)

    Click here

  40. REMOVE FRONT DRIVE SHAFT ASSEMBLIES (for TMMT Made)

    Click here

  41. INSTALL ENGINE HANGERS


    1. A005OG5

      Disengage the 3 clamps from the wire harness clamp bracket.

    2. Remove the nut to separate the engine wire from the wire harness clamp bracket.

    3. Remove the bolt and wire harness clamp bracket from the cylinder head sub-assembly.

    4. A005P6R

      Separate the bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH.

    5. A005P73C04
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      B00495X Bolt

      Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-47060
      No. 2 Engine Hanger 12282-47030
      Bolt 91552-81030

  42. INSTALL ENGINE SUPPORT BRIDGE


    1. A005PDM

      Remove the clip and the neck from the windshield washer jar assembly.

    2. Install SST to the vehicle body as shown in the illustration.

      A005QBUC01
      *a Support Shaft *b Front Side Member
      *c Front Suspension Nut - -
      SST
      09940-10020

      CAUTION:


      • A005PBRC01
        *a Support Shaft
        *b Front Side Member

        Make sure that no oil or grease is on the front side member, and set the support shaft on the level surface of the front side member.

      • The engine support bridge may fall off if any oil or grease is still on or it is installed on the unlevel surface.

      Note


      • Prevent SST from contacting the vehicle body exterior and windshield glass.

      • To prevent damage to the engine hood, place pieces of cloth between the engine hood and SST.

      • Lightly shake SST by hand to make sure it is securely installed before performing work.

    3. A005PI3C01
      *a Support Shaft
      *b Sub Beam
      *c Front Side Member
      *d Threaded Portion

      Turn the threaded portion of each support shaft to adjust its height until the sub beams are parallel to the ground.

    4. Install the chain block to the sling bracket.

      A005OE8C01
      *a Chain Block *b Sling Bracket
      *c Fuse Shackle *d Shackle (A)

    5. Install the division bar to the chain block with the shackles.

      CAUTION:


      • A005Q4HC01
        *a Fuse Shackle
        *b Shackle (A)

        Make sure the fuse shackle is on the chain block side and the shackle (A) is on the division bar side as shown in the illustration so that the fuse bolt is visible and can be checked for deformation easily.

      • If the fuse shackle is installed upside down, deformation of the fuse bolt will not be visible and cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with automatic transaxle assembly may fall.

      • A005PA7C01
        *a Fuse Shackle
        *b Fuse Bolt

        Make sure that the fuse bolt of the fuse shackle is free of damage, such as deformation or cracks. If damaged, replace the fuse shackle.

      • If a deformed fuse bolt is used, it cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with transaxle assembly may fall.

    6. Connect the division bar to the No. 1 engine hanger with the shackle (A) and chain.

      A005OJ5C01
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *a Division Bar *b Shackle (A)
      *c Chain - -

      Note

      Connect the 2nd link of the chain to the No. 1 engine hanger.

    7. Connect the division bar to the No. 2 engine hanger with the shackle (A) and chain.

      Note

      Connect the 2nd link of the chain to the No. 2 engine hanger.

    8. A005P09C02
      *a 120 mm (4.72 in.) or more

      Make sure the distance between the chain block assembly and suspension ring is 120 mm (4.72 in.) or more.

      Tech Tips

      If the suspension height is less than 120 mm, adjust the links of the chain which connect the division bar and engine hanger.

    9. Adjust the positions of the chain block assembly, support brackets and main beam so that the chain of the chain block assembly is perpendicular to the main beam and the length of the main beam on the outer side of the support bracket LH and RH is the same as shown in the illustration.

      A005P9VC01
      *a Chain Block *b Main Beam
      *c Dimension (A) *d Dimension (B)
      *e Right to Left Adjustment *f Front to Rear Adjustment

      CAUTION:


      • To prevent the engine with automatic transaxle assembly from falling, make sure that the length of dimension (A) and dimension (B) are equal.

      • A005Q8MC01
        *a Main Beam

        Do not perform any procedures if the length of dimension (A) and dimension (B) are not equal.

      • Performing any procedure when the length of dimension (A) and dimension (B) are not equal may cause the engine assembly with automatic transaxle assembly and engine support bridge to fall, possibly causing serious injury.

    10. Confirm the appropriate installation state of the engine support bridge and tighten the 6 wing bolts and 2 bolts.

      A005P2CC01
      *a Wing Bolt *b Bolt
      Torque:
      Bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      CAUTION:


      • A005PIP

        Do not perform any procedures before tightening the bolts to the specified torque.

      • Performing procedures without tightening the bolts to the specified torque, may cause the engine support bridge to fall.

    11. A005PXIC01
      *a Turn

      Tighten the chain block assembly until it cannot be moved any further by hand.

  43. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  44. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Click here

  45. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  46. REMOVE NO. 2 ENGINE MOVING CONTROL ROD


    1. A005Q21

      Remove the 4 bolts and No. 2 engine moving control rod from the continuously variable transaxle assembly.

  47. SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. A005OHRC01
      *a Lashing Belt

      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.

  48. REMOVE STARTER ASSEMBLY (for Valeo Made Cold Area Specification Vehicles)

    Click here

  49. REMOVE STARTER ASSEMBLY (for Valeo Made except Cold Area Specification Vehicles)

    Click here

  50. REMOVE STARTER ASSEMBLY (for Denso Made without Stop and Start System)

    Click here

  51. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  52. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A005PQC

      Remove the flywheel housing under cover from the stiffening crankcase assembly.

  53. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. A005Q8C

      Turn the crankshaft to gain access to the 6 drive plate and torque converter assembly setting bolts and remove each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

      Tech Tips

      There will be one black colored drive plate and torque converter assembly setting bolt.

  54. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR


    1. A005OI2

      Remove the bolt and nut to separate the transverse engine engine mounting insulator from the engine mounting bracket LH.

    2. A005P01

      Remove the nut and 4 bolts.

    3. Remove the transverse engine engine mounting insulator from the vehicle body.

  55. REMOVE ENGINE MOUNTING STAY LH


    1. A005OIG

      Remove the 2 bolts and engine mounting stay LH from the continuously variable transaxle assembly.

  56. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET


    1. A005PID

      Remove the 3 bolts and transverse engine engine mounting bracket from the continuously variable transaxle assembly.

  57. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. A005Q2FN01

      Remove the 7 bolts and continuously variable transaxle assembly from the engine assembly.

      Note

      To prevent damage to the 2 knock pins, do not pry between the continuously variable transaxle assembly and engine assembly.

      Tech Tips


      • Bolt (A): Remove from continuously variable transaxle assembly side.

      • Bolt (B): Remove from engine assembly side.

  58. REMOVE TORQUE CONVERTER ASSEMBLY


    1. A005OBT

      Remove the torque converter assembly from the continuously variable transaxle assembly.

      Note

      Remove the torque converter assembly from the input shaft horizontally.

  59. REMOVE CVT OIL PUMP TYPE T OIL SEAL

    Note


    • Do not remove the front oil pump assembly from the CVT main body, as there is a possibility of the entry of dust and foreign matter.

    • Clean the work area, the tools to be used, and other equipment, etc. thoroughly before the operation, as there is the possibility that a CVT malfunction, which could prevent the vehicle from being able to be driven, could occur if dust or fine foreign matter enters the CVT.

    • Do not use cotton work gloves, cloths, or paper towels, etc. that may produce lint, dust or foreign matter.

    • Perform the operation as quickly as possible, as dust and foreign matter could enter the CVT while the torque converter assembly is removed.

    • Do not use an air gun until the torque converter assembly has been installed, as it could cause dust and foreign matter to be stirred up.


    1. Clean the tips of both the claws of SST and the center bolt.

      SST
      09308-10010
    2. A005OJSN01

      Using SST, remove the CVT oil pump type T oil seal.

      Note

      Pay attention to the angle of the claws when opening them, and ensure that they do not come into contact with the oil pump housing, as there is the possibility that metal particles could be produced if they do.

  60. REMOVE TRANSFER ASSEMBLY

    Click here

  61. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

    Click here

  62. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A005P8R

      Remove the 4 bolts and 4 wire harness clamp brackets from the continuously variable transaxle assembly.

  63. REMOVE NO. 1 HEATER BRACKET SUB-ASSEMBLY


    1. A005P2Z

      Separate the No. 1 breather plug (CVT) from the clamp.

    2. A005OGH

      Remove the clamp from the No. 1 heater bracket sub-assembly.

    3. A005Q9O

      Remove the bolt and No. 1 heater bracket sub-assembly from the continuously variable transaxle assembly.

  64. REMOVE STRAIGHT SCREW PLUG

    Tech Tips

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


    1. A005PW2

      Remove the straight screw plug and gasket from the continuously variable transaxle assembly.

  65. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

    Tech Tips

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


    1. A005Q9Z

      Remove the transmission breather hose sub-assembly from the continuously variable transaxle assembly.

    2. A005Q9FC01
      *1 No. 1 Breather Plug (CVT)
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug (CVT)
      *4 O-ring

      Remove the No. 1 breather plug (CVT) and No. 2 breather plug (CVT) from the breather plug hose.

    3. Remove the O-ring from the No. 2 breather plug (CVT).

  66. INSPECT TORQUE CONVERTER ASSEMBLY

    Click here

  67. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here