CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION


  1. INSTALL TRANSMISSION CASE PLUG ASSEMBLY

    Tech Tips

    After replacing the continuously variable transaxle assembly, perform the following procedure.


    1. A0117ZE

      Apply Toyota Genuine CVT Fluid TC to the O-ring on a new transmission case plug.

    2. Install the transmission case plug to the continuously variable transaxle assembly.

  2. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A0117Y2E02

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

      Torque:
      Bolt A
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Bolt B
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    2. Install the 2 wire harness clamp brackets to the continuously variable transaxle assembly with the 2 bolts.

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

  3. 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 }

  4. INSTALL ENGINE MOUNTING BRACKET LH


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

    2. A0119ATE07
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A0117NXE02

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

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

      Tech Tips

      1 (Temporarily tighten) →

      2 (Fully tighten) →

      3 (Fully tighten) →

      1 (Fully tighten)

  5. INSTALL ENGINE MOUNTING STAY LH


    1. A011BH6E03

      Install the engine mounting stay LH to the continuously variable transaxle assembly and the engine mounting bracket LH with the 2 bolts.

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

      Tech Tips

      1 (Temporarily tighten) →

      2 (Fully tighten) →

      1 (Fully tighten)

  6. 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 attach the CVT oil pump type T oil seal by pressing it onto the installation surface of the oil pump housing manually.

    3. A0118UZE01

      Clean the oil seal contact section of the SST and the area around it.

    4. Using SST, drive the CVT oil pump type T oil seal in evenly, as far as the side surface of the oil pump housing.

      SST
      09309-36010

      Note


      • Drive the oil seal in gradually, while visually checking the parallelism.

      • After the installation, confirm that the oil seal has been driven in as far as the side surface of the oil pump housing.

      • Wipe off any grease that has oozed out with your hand.

      Tech Tips

      The oil seal should be driven in between 0 and 0.5 mm (as measured from the side surface of the oil pump housing).

  7. INSTALL TORQUE CONVERTER ASSEMBLY


    1. Clean and degrease the 6 holes for the torque converter set bolts.

    2. A011ANHE02
      Text in Illustration
      *a Protrusion
      *b Matchmark

      Make a matchmark to indicate the position of the torque converter protrusion (*1).

    3. A011BO9E02
      Text in Illustration
      *a Wide Groove
      *b Narrow Groove
      *c Matchmark

      Make a matchmark on the housing to indicate the position of the groove in the front oil pump drive gear.

      Note

      Make the housing matchmark at the wide groove. The matchmark position must be correct to prevent damage.

    4. A0117O8E02
      Text in Illustration
      *1 Oil Seal
      *a Matchmark

      Align the matchmarks on the housing and torque converter and engage the input shaft splines with the turbine runner.

      Note


      • Maintain the torque converter in a horizontal position when installing the input shaft.

      • Be sure to not damage the oil seal.

    5. A011977E02
      Text in Illustration
      *a Matchmark

      Rotate the torque converter to engage the stator shaft splines with the stator splines.

      Note

      Maintain the torque converter in a horizontal position when installing the stator shaft.

      Tech Tips

      Rotate the torque converter about 180 degrees.

    6. A01192YE02
      Text in Illustration
      *a Matchmark

      Rotate the torque converter clockwise until the matchmark aligns with the matchmark on the case, and then engage the grooves in the oil pump drive gear with the claws in the torque converter.

      Note


      • Maintain the torque converter in a horizontal position when installing the input shaft and stator shaft.

      • Do not push the torque converter while aligning the matchmarks.

    7. A0118F7E02
      Text in Illustration
      *a Continuously Variable Transaxle Installation Surface
      *b Torque Converter Installation Surface

      Using a vernier caliper, measure the distance from the continuously variable transaxle fitting surface on the engine to the torque converter fitting surface on the drive plate (dimension A).

    8. A01189AE01

      Using a vernier caliper and a straightedge, measure the distance from the set block to the housing end (dimension B) and check that dimension B is greater than dimension A.

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

      Note

      Ensure that the torque converter is inserted all the way into the continuously variable transaxle assembly. If the converter is not inserted sufficiently when the continuously variable transaxle assembly is installed onto the engine, the continuously variable transaxle assembly and torque converter could be damaged.

  8. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. A0117CTE01
      Text in Illustration
      *1 Knock Pin
      *2 Crankshaft
      *3 Clutch Spline Grease

      Confirm that 2 knock pins are on the transaxle contact surface of the engine cylinder block before transaxle installation.

    2. Apply clutch spline grease to the round of the crankshaft contact surface with the torque converter centerpiece.

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      Approximately 1 g (0.353 oz)
    3. A0117IFE02
      Text in Illustration
      *1 Knock Pin Hole

      Maintain the engine and continuously variable transaxle assembly in a horizontal position, align the knock pins and holes , and tighten the 9 bolts shown the illustration.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      Bolt C
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note


      • Confirm that there are 2 knock pins on the fitting surface of the engine block before installing the continuously variable transaxle assembly.

      • Do not twist or apply excessive force to the continuously variable transaxle assembly.

      • Check that the torque converter rotates smoothly after installation of the continuously variable transaxle assembly.

      Tech Tips


        Bolt length

      • Bolt A: 45 mm (1.77 in.)

      • Bolt B: 45 mm (1.77 in.)

      • Bolt C: 35 mm (1.38 in.)

  9. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. Clean and degrease the 6 drive plate and torque converter setting bolts.

    2. A0119ATE07
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Use SST to hold the crankshaft pulley in place.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    4. Install the 6 torque converter set bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Tighten the black-colored bolt first, and then tighten the 5 silver-colored bolts.

  10. INSTALL STARTER ASSEMBLY


    1. Install the starter assembly with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    2. Connect the connector.

    3. Connect terminal 30 with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    4. Close the terminal cap.

  11. INSTALL ENGINE MOUNTING CONTROL BRACKET


    1. A0117AVE02

      Install the engine mounting control bracket to the continuously variable transaxle assembly with the 4 bolts.

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

      Tech Tips

      1 (Temporarily tighten) →

      3 (Fully tighten) →

      2 (Fully tighten) →

      1 (Fully tighten)

  12. INSTALL ENGINE WIRE


    1. A0116XKE01
      Text in Illustration
      *1 Bolt
      *2 Park/Neutral Position Switch Connector
      *3 Transmission Wire Connector
      *4 Transmission Revolution Sensor Connector (NT)
      *5 Transmission Revolution Sensor Connector (NIN)

      Engage the 3 clamps and install the engine wire to the continuously variable transaxle assembly.

    2. Connect the park/neutral position switch connector, transmission wire connector and the 2 transmission revolution sensor connectors (NIN, NT).

    3. Install the engine wire to the continuously variable transaxle assembly with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    4. A011AG7E01
      Text in Illustration
      *1 Transmission Revolution Sensor Connector (NOUT)
      *2 Oil Pressure Sensor Connector
      *3 Oxygen Sensor Connector

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

    5. Connect the oxygen sensor connector, oil pressure sensor connector and the transmission revolution sensor connector (NOUT).

  13. INSTALL WATER BY-PASS HOSE ASSEMBLY


    1. A0117BJE02
      Text in Illustration
      *a Rear of Vehicle

      Connect the 2 water by-pass hoses to the oil cooler with the 2 clamps.

      Note

      Securely push the hoses over each pipe fitting on the transmission oil cooler until the hoses contact the rib on each pipe fitting.

    2. Install the water by-pass hose to the continuously variable transaxle assembly with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
    3. A011AZNE02

      Engage the clamp and install the breather hose to the breather hose clamp.

      Text in Illustration
      A0118KG Paint Mark

      Tech Tips


      • Install the breather hose clamp so that the top end of it overlaps the painted area.

      • Install the breather hose clamp so that its protuberance is within the painted area.

  14. INSTALL DRIVE SHAFT HEAT INSULATOR BRACKET


    1. Install the drive shaft heat insulator bracket to the engine with the 2 bolts.

      Torque:
      16 N*m  { 166 kgf*cm, 12 ft.*lbf }

  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  16. RESET MEMORY (CVT initialization)

    Note

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