CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL BREATHER PLUG HOSE

    Tech Tips

    Perform this procedure only when replacement of the breather plug hose is necessary.


    1. Install the No. 1 breather plug (CVT) to the breather plug hose.

    2. Install the breather plug hose with the No. 1 breather plug (CVT) to the continuously variable transaxle assembly.

  2. INSTALL HEAD STRAIGHT SCREW PLUG

    Tech Tips

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


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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  3. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the No. 1 water hose clamp bracket, 4 wire harness clamp brackets and breather hose clamp bracket to the continuously variable transaxle assembly with the 6 bolts.

      A005IMJE07
      Text in Illustration
      *1 Water By-pass Hose Clamp *2 No. 1 Water Hose Clamp Bracket
      *3 Wire Harness Clamp Bracket *4 Breather Hose Clamp Bracket
      Torque:
      Bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Bolt B
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Bolt C
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Install the water by-pass hose clamp to the No. 1 water hose clamp bracket.

  4. CONNECT NO. 1 BREATHER PLUG (CVT)


    1. Connect the No. 1 breather plug (CVT) to the breather hose clamp bracket.

  5. INSTALL ENGINE MOUNTING BRACKET LH


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

    2. A005IU8E16
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the bolt within 3 minutes of applying adhesive.

    3. Temporarily install the engine mounting bracket LH with the 3 bolts.

    4. A005HS8E02

      Fully tighten the 3 bolts in the order shown in the illustration.

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

  6. 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 }

  7. INSTALL ENGINE MOVING CONTROL ROD


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

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

  8. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the engine moving control rod to the front suspension crossmember sub-assembly with the bolt.

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

  9. 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. A005L0SE01

      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, until it is even with the side surface of the oil pump housing.

      SST
      09309-36010

      Note


      • Drive the oil seal in gradually, while visually checking that it is even.

      • After the installation, confirm that the oil seal has been driven in until it is even with the side surface of the oil pump housing.

      • Wipe any extra grease off with your hand.

      Tech Tips

      The oil seal should be driven in between 0 and 0.5 mm (0 to 0.0197 in.) as measured from the side surface of the oil pump housing.

  10. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A005JQ7E04
      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. A005LAGE02
      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. A005MG7E03
      Text in Illustration
      *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

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

    4. A005KR1E03
      Text in Illustration
      *1 Oil Seal
      *a Matchmark

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

      Note


      • Do not damage the oil seal.

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

    5. A005KW3E02
      Text in Illustration
      *1 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.

      Note


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

      • Do not damage the oil seal.

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

    6. Clean the torque converter assembly set bolt holes.

    7. A005L5XE02
      Text in Illustration
      *1 Engine Surface
      *2 Drive Plate Surface

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

    8. A005JYPE01

      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 assembly not sufficiently inserted, the torque converter assembly may be damaged.

      • Do not include the thickness of the set block.

  11. INSTALL ENGINE ASSEMBLY


    1. A005J0NE02
      Text in Illustration
      *1 Torque Converter Assembly Centerpiece
      *2 Crankshaft

      Apply clutch spline grease to the round 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. A005IABE02
      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 use excess force when installing the continuously variable transaxle assembly.

      • Check that the torque converter assembly rotates.

      Tech Tips


      • Bolt A: Install from transaxle side

      • Bolt B: Install from engine side

  12. INSTALL STARTER ASSEMBLY

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  13. INSTALL ENGINE WIRE


    1. Connect the 5 connectors and 9 clamps.

  14. CONNECT WATER BY-PASS HOSE


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

    2. Connect the water by-pass hose to the water by-pass hose clamp.

  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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  16. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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  17. INSTALL FLYWHEEL HOUSING UNDER COVER

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  18. RESET MEMORY

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