БЕССТУПЕНЧАТАЯ ТРАНСМИССИЯ В СБОРЕ УСТАНОВКА


  1. INSTALL TRANSMISSION CASE PLUG ASSEMBLY

    Tech Tips

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


    1. A0117ZE

      Apply a light coat of Toyota Genuine CVT fluid FE to the O-ring of a new transmission case plug assembly.

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

      Note

      Make sure that the O-ring is not cracked or moved out of place when installing the transmission case plug assembly.

  2. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A011AP8E02

      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  { 130 kgf*cm, 9 ft.*lbf }
    2. A011A2E

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

      Torque:
      13 N*m  { 130 kgf*cm, 9 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. A0119ATE20
      Text in Illustration
      *a 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

      Note

      To prevent contamination by foreign matter, install immediately after applying adhesive.

    3. A0119SUE02
      Text in Illustration
      *a Temporarily Tighten

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

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

  5. INSTALL ENGINE MOUNTING STAY LH


    1. A011BH6E04
      Text in Illustration
      *a Temporarily Tighten

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

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

  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 SST and the area around it.

    4. 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.

      SST
      09309-36010
      Drive in depth
      -0.2 to 0.2 mm (-0.00787 to 0.00787 in.)

      Note


      • Drive the CVT oil pump type T oil seal in gradually, while visually checking the parallelism.

      • After the installation, confirm that the CVT oil pump type T 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.

  7. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A011BO9E03
      Text in Illustration
      *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 housing to indicate the position of the groove.

      Note


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

      • The matchmark position must be correct to prevent damage.

    2. A011ANHE04
      Text in Illustration
      *a Key
      *b Matchmark

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

    3. A0117O8E03
      Text in Illustration
      *1 CVT Oil Pump Type T Oil Seal
      *a Matchmark

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

      Note


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

      • Do not damage the CVT oil pump type T oil seal.

    4. A011977E03
      Text in Illustration
      *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


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

      • Do not damage the CVT oil pump type T oil seal.

    5. A01192YE03
      Text in Illustration
      *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 housing and insert the key of the torque converter assembly into the groove of the oil pump drive gear.

      Note


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

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

      • Do not damage the CVT oil pump type T oil seal.

    6. Clean the drive plate and torque converter setting bolt holes.

    7. A011AU5E02
      Text in Illustration
      *a Engine Surface
      *b Drive Plate Surface

      Using a vernier caliper and a straightedge, measure 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.

    8. A01189AE03

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

      Standard distance
      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.

  8. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. A011803E02
      Text in Illustration
      *1 Knock Pin
      *2 Crankshaft
      *a Contacts Torque Converter Assembly Centerpiece

      Apply clutch spline grease to the circumference 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. Confirm that the 2 knock pins are installed on the engine assembly and are not damaged.

    3. A0117IFE03

      Install the continuously variable transaxle assembly to the engine assembly with the 9 bolts.

      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


      • 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 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. A0119ATE20
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 6 drive plate and torque converter setting bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      To prevent contamination by foreign matter, install immediately after applying adhesive.

    3. A011BCDE01

      Use SST to hold the crankshaft pulley in place.

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

    4. Install the 6 drive plate and torque converter setting bolts.

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

      Note


      • First install the black-colored bolt, and then the remaining 5 silver-colored bolts.

      • Do not start the engine for at least 1 hour after installing the drive plate and torque converter setting bolts.

  10. INSTALL STARTER ASSEMBLY


    1. A011B4H

      Install the starter assembly with the 2 bolts.

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

    2. Connect the connector.

    3. Connect the cable to 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. A0117AVE03
      Text in Illustration
      *a Temporarily Tighten

      Install the engine mounting control bracket to the continuously variable transaxle assembly with the 4 bolts in the order shown in the illustration.

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

  12. INSTALL ENGINE WIRE


    1. 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, transmission revolution sensor (NIN) connector and the transmission revolution sensor (NT) connector.

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

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

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

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

  13. INSTALL WATER BY-PASS HOSE ASSEMBLY


    1. A0117BJ

      Connect the 2 water by-pass hoses to the transmission oil cooler assembly with the 2 hose clips.

      Text in Illustration
      A0117XZ Rear of Vehicle

      Note

      Securely push the water by-pass hoses over each pipe fitting on the transmission oil cooler assembly until the hoses contact the rib on each pipe fitting.

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

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
    3. A0119XQE01

      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 EXHAUST MANIFOLD


    1. A0117KAE01

      Place the 2 new gaskets and install the exhaust manifold, tightening the nuts and bolts in the sequence shown in the illustration.

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

  15. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A0119K7E01

      Install the No. 1 exhaust manifold heat insulator, tightening the nuts and bolts in the sequence shown in the illustration.

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

  16. INSTALL AIR FUEL RATIO SENSOR


    1. A011AFUE01

      Using SST, install the air fuel ratio sensor to the exhaust manifold.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) Click here.

      • This torque value is effective when SST is parallel to the torque wrench.

    2. Install the wire harness clamp and connect the air fuel ratio sensor connector.

  17. INSTALL MANIFOLD STAY


    1. A0117BI

      After temporarily tightening the manifold stay until the nut is firm against the exhaust manifold, fully tighten the manifold stay to the block with the 2 bolts and then fully tighten the nut on the exhaust manifold side.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  18. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  19. RESET MEMORY (CVT initialization)

    Click here