CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

INSTALL TORQUE CONVERTER ASSEMBLY

1. Clean the torque converter assembly set bolt holes.

2. 

   Using a vernier caliper and straightedge, measure dimension "A" between the continuously variable transaxle assembly contact surface of the engine assembly*1 and the torque converter assembly contact surface of the drive plate*2. (#)

   Note:

   Make sure to deduct the thickness of the straightedge.

3. 

   Turn the front oil pump drive gear so that the groove is at the top and put a matchmark on the housing.

   Table 1. Text in Illustration

   *a	Matchmark
   *b	Groove

4. 

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

   Table 2. Text in Illustration

   *a	Key
   *b	Matchmark

5. 

   Align the matchmark on the housing with the one on the torque converter assembly and mesh the splines of the input shaft with the turbine runner splines.

   Table 3. Text in Illustration

   *a

   Matchmark

   Note:

   Install the torque converter assembly horizontally to the input shaft.

6. 

   Rotate the torque converter assembly and mesh the splines of the stator shaft with the stator splines.

   Table 4. Text in Illustration

   *1	Oil Seal
   *a	Matchmark

   Note:
   

   • Do not damage the oil seal.

   • Install the torque converter assembly horizontally to the input shaft.

   Tip:

   Rotate the torque converter assembly approximately 180°.

7. 

   Rotate the torque converter assembly again, align the matchmark on the housing with the one on the torque converter assembly and fit the key of the torque converter assembly into the groove of the oil pump drive gear.

   Table 5. Text in Illustration

   *1	Oil Seal
   *a	Matchmark

   Note:
   

   • Do not push the torque converter assembly excessively when rotating it.

   • Do not damage the oil seal.

   • Install the torque converter assembly horizontally to the input shaft.

8. 

   Using a vernier caliper and straightedge, measure dimension "B" shown in the illustration and check that dimension "B" is greater than dimension "A" (which was measured in step (#)).

   Standard
   A + 1 mm (0.0394 in.) or more

   Note:

   Subtract the thickness of the straightedge from the measured value to gain dimension "B".

INSTALL ENGINE MOUNTING BRACKET LH

1. Install the engine mounting bracket LH to the continuously variable transaxle assembly with the 3 bolts.

   64 N*m

   653 kgf*cm

   47 ft.*lbf

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.

   12 N*m

   122 kgf*cm

   9 ft.*lbf

INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

1. 

   Apply clutch spline grease to the circumference of the crankshaft contact surface with the torque converter assembly centerpiece.

   Clutch Spline Grease
   Toyota Genuine Clutch Spline Grease or equivalent
   Maximum Spread
   About 1 g (0.0353 oz.)

   Table 6. Text in Illustration

   *1	Torque Converter Assembly Centerpiece
   *2	Crankshaft

2. Confirm that the 2 knock pins are installed to the continuously variable transaxle assembly contact surface of the engine assembly before installing the continuously variable transaxle assembly.

3. Clean and degrease the bolt hole of the bolt (D).

4. 

   While keeping the engine assembly and continuously variable transaxle assembly level, align the knock pins with knock pin holes, and temporarily tighten the 8 bolts ((A), (B) and (C)) shown in the illustration.

   Table 7. Text in Illustration

   *1

   Knock Pin

   Note:
   

   • Make sure that the bolts and bolt holes (A)(*) and (D)(*) shown in the illustration are free of oil. Clean them if necessary.

   • Do not forcibly pry on the continuously variable transaxle assembly.

   • Make sure that the torque converter assembly rotates.

   Tip:
   

   • Bolt Length

   • for Bolt (A) : 55 mm (2.17 in.)

   • for Bolt (B) : 65 mm (2.56 in.)

   • for Bolt (C) : 32 mm (1.26 in.)

5. 

   Apply adhesive to 2 or 3 threads on the end of a new bolt (D).

   Table 8. Text in Illustration

   *a

   Adhesive

   Note:
   

   • Do not reuse bolt D.

   • After applying adhesive 1324, install the bolt (D) within 3 minutes to prevent foreign matter from attaching it.

   Tip:

   for Bolt (D) : 42 mm (1.65 in.)

6. 

   Temporarily tighten the bolt (D) shown in the illustration.

7. 

   Tighten the 9 bolts ((A), (B), (C) and (D)) shown in the illustration.

   for Bolt (A)
   64 N*m	653 kgf*cm	47 ft.*lbf
   for Bolt (B)
   46 N*m	469 kgf*cm	34 ft.*lbf
   for Bolt (C)
   44 N*m	449 kgf*cm	32 ft.*lbf
   for Bolt (D)
   20 N*m	204 kgf*cm	15 ft.*lbf

   Note:
   

   • Make sure that the torque converter assembly rotates.

   • In order to ensure the sealing performance, leave the vehicle as it is for at least 1 hour after installing the bolt (D). (Do not start the engine.)

INSTALL OIL COOLER (w/o Air Cooled Transmission Oil Cooler)

1. Install the oil cooler to the continuously variable transaxle assembly with the 3 bolts.

   12 N*m

   120 kgf*cm

   8 ft.*lbf

2. Install the 2 oil cooler hoses and slide the 2 clips to secure them.

3. Install the water by-pass hose and 2 oil cooler hoses and slide the 3 clips to secure them.

INSTALL OIL COOLER (w/ Air Cooled Transmission Oil Cooler)

1. Install the oil cooler to the continuously variable transaxle assembly with the 3 bolts.

   12 N*m

   120 kgf*cm

   8 ft.*lbf

2. Install the 2 water by-pass hoses and slide the 2 clips to secure them.

3. Install the 2 oil cooler hoses and slide the 4 clips to secure them.

INSTALL WIRE HARNESS CLAMP BRACKET

1. 

   Install the shift cable bracket and 2 wire harness clamp brackets to the continuously variable transaxle assembly with the 2 bolts.

   for Bolt (A)
   5.0 N*m	51 kgf*cm	44 in.*lbf
   for Bolt (B)
   8.4 N*m	86 kgf*cm	74 in.*lbf

2. Install the ground cable to the wire harness clamp bracket with the bolt.

   8.4 N*m

   86 kgf*cm

   74 in.*lbf

   Table 9. Text in Illustration

   *1	Ground Cable

INSTALL ENGINE WIRE

1. Install the 2 wire harness clamps and connect the oil pressure sensor connector to the continuously variable transaxle assembly.

2. Install the 4 wire harness clamps and connect the 3 revolution sensor connectors, park/neutral position switch assembly connector and transmission wire connector to the continuously variable transaxle assembly.

INSTALL REAR ENGINE MOUNTING BRACKET

1. Install the rear engine mounting bracket to the continuously variable transaxle assembly with the 3 bolts.

   45 N*m

   459 kgf*cm

   33 ft.*lbf

INSTALL FRONT ENGINE MOUNTING BRACKET

1. Install the front engine mounting bracket to the continuously variable transaxle assembly with the 3 bolts.

   64 N*m

   653 kgf*cm

   47 ft.*lbf

INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

RESET MEMORY

1. Perform Reset Memory (CVT initialization) when replacing the continuously variable transaxle assembly (Click here).