CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL W/HEAD STRAIGHT SCREW PLUG

    Tech Tips

    Perform this procedure only when replacement of the continuously variable transaxle assembly is necessary.


    1. Install the w/head straight screw plug to the continuously variable transaxle assembly with a new gasket.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

  2. INSTALL CVT OIL PUMP TYPE T OIL SEAL


    1. Ensure that there is no dirt or foreign matter on your hands, and then apply genuine TOYOTA MP grease No.2 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. A005L0SE01

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

    4. Using the 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 0.5mm (as measured from the side surface of the oil pump housing).

  3. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A005H16E04
      Text in Illustration
      *a Matchmark
      *b 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.

    2. A005M96E08
      Text in Illustration
      *1 Key
      *a Matchmark

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

    3. A005LBYE03
      Text in Illustration
      *a Matchmark

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

      Note

      Install the torque converter to the input shaft while keeping it horizontal.

    4. A005GTSE03
      Text in Illustration
      *1 Oil Seal
      *a Matchmark

      Rotate the torque converter approximately 180° and engage the splines of the stator shaft with the stator.

      Note


      • Do not damage the oil seal.

      • Install the torque converter to the input shaft while keeping it horizontal.

    5. A005IC4E03
      Text in Illustration
      *1 Oil Seal
      *a Matchmark

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

      Note


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

      • Do not damage the oil seal.

      • Install the torque converter to the input shaft while keeping it horizontal.

    6. Clean the torque converter set bolt holes.

    7. A005HJJE02
      Text in Illustration
      *1 Engine Surface
      *2 Drive Plate Surface Groove

      Using a vernier caliper and straightedge, measure dimension "A" between the transaxle contact surface of the engine and the torque converter contact surfaces of the drive plate.

      Note

      Make sure to deduct the thickness of the straightedge.

    8. A005JIBE01

      Using a vernier caliper and 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
      A + 1 mm (0.0394 in.) or more

      Note


      • Make sure to deduct the thickness of the straightedge.

      • If the transaxle is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.

  4. INSTALL ENGINE MOVING CONTROL ROD


    1. Install the engine moving control rod to the continuously variable transaxle with the 4 bolts.

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

  5. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the engine moving control rod with the bolt.

      Torque:
      120 N*m  { 1220 kgf*cm, 89 ft.*lbf }

  6. INSTALL ENGINE ASSEMBLY

    A005GHHE02
    Text in Illustration
    *1 Torque Converter Centerpiece
    *2 Crankshaft

    1. Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter centerpiece.

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      About 1 g (0.0353 oz.)
    2. A005J7CE01
      Text in Illustration
      *1 Knock Pin

      While keeping the engine and continuously variable transaxle assembly horizontal, align the knock pins with the holes in the continuously variable transaxle assembly and install the 7 bolts shown in the illustration.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }

      Note


      • Confirm that the 2 knock pins are installed to the transaxle contact surface of the engine cylinder block before installing the transaxle.

      • Do not forcibly pry on the Check that the torque converter rotates..

      • Check that the torque converter rotates.

      Tech Tips


      • Bolt A: Install from transaxle side

      • Bolt B: Install from engine side

  7. INSTALL STARTER ASSEMBLY

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  8. INSTALL FLYWHEEL HOUSING SIDE COVER

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  9. INSTALL ENGINE MOUNTING BRACKET LH


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

    2. A005IU8E26
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 4 bolts.

      Adhesive:
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Install the engine mounting bracket LH to the continuously variable transaxle with the 4 bolts.

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

  10. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


    1. Install the No. 1 transmission control cable bracket to the continuously variable transaxle with the 2 bolts.

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

  11. INSTALL WIRE HARNESS CLAMP BRACKET

    A005GPVE02
    Text in Illustration
    *a Water By-pass Hose Clamp - -

    1. Install the 3 wire harness clamp brackets and breather hose clamp bracket to the continuously variable transaxle with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      (bolt A)
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      (bolt B)
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      (bolt C)

    2. Attach the water by-pass hose clamp to the wire harness clamp bracket.

  12. CONNECT ENGINE WIRE


    1. Attach the wire harness clamp and connect the 2 revolution sensor connectors and transmission wire connector to the continuously variable transaxle.

    2. Attach the 2 wire harness clamps and connect the park/neutral position switch connector to the continuously variable transaxle.

    3. Attach the 5 wire harness clamps and connect the oil pressure sensor connector, revolution sensor connector and park/neutral position switch connector to the continuously variable transaxle.

  13. CONNECT WATER BY-PASS HOSE


    1. Connect the 2 water by-pass hoses with the 2 hose clips.

      Note

      Make sure the paint marks and pinching portion of each clip are facing the direction shown in the illustration.

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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  15. RESET MEMORY

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