CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL TRANSMISSION CASE PLUG ASSEMBLY


    1. A005HUR

      Apply Toyota Genuine CVT Fluid TC to the O-rings on new 2 transmission case plugs.

  2. INSTALL WIRE HARNESS CLAMP BRACKET

    A005IM7E01

    1. Install the 3 wire harness clamp brackets with the 4 bolts.

      Torque:
      for Bolt A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for Bolt B
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  3. 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 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 with the 4 bolts.

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

  4. INSTALL ENGINE MOVING CONTROL ROD


    1. A005GV3E02

      Install the engine moving control rod with the 3 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
      Bolt Length
      Bolt Length
      A 52.0 mm (0.984 in.)
      B 33.5 mm (1.319 in.)

  5. INSTALL CVT OIL PUMP TYPE T OIL SEAL


    1. A005L0SE06

      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. 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.

      Standard oil seal drive in depth
      -0.2 to 0.2 mm
      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.

  6. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A005HPYE03
      Text in Illustration
      *a Wide Groove
      *b Narrow Groove
      *c Matchmark

      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 location of the wide groove.

      • The matchmark position must be correct to prevent damage.

    2. A005IWNE02
      Text in Illustration
      *a Key
      *b Matchmark

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

    3. A005LY6E02
      Text in Illustration
      *a Matchmark
      *b Oil Seal

      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. A005KYLE01
      Text in Illustration
      *a Matchmark
      *b Oil Seal

      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. A005M3BE01
      Text in Illustration
      *a Matchmark
      *b Oil Seal

      Rotate the torque converter approximately 180° 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.

      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. A005LTRE03
      Text in Illustration
      *a CVT Installation Surface
      *b Torque Converter Installation Surface

      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. A005J9UE01

      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 distance
      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.

  7. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. A005L6AE02
      Text in Illustration
      *1 Torque converter centerpiece
      *2 Crankshaft

      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
      Approximately 1 g (0.0353 oz)
    2. A005LN8E03
      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 8 bolts shown in the illustration.

      Torque:
      for Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      for Bolt B
      39 N*m  { 398 kgf*cm, 29 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 continuously variable transaxle assembly.

      • Check that the torque converter rotates.

  8. 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 }

  9. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  10. INSTALL FLYWHEEL HOUSING SIDE COVER (w/ Stop And Start System)

    Click here

  11. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  12. INSTALL FLYWHEEL HOUSING SIDE COVER (w/o Stop And Start System)

    Click here

  13. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


    1. Install the No. 1 transmission control cable bracket with the 2 bolts.

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

    2. Engage the clamp and install the engine wire.

  14. INSTALL ENGINE WIRE


    1. Install the ground cable to the continuously variable transaxle with the bolt and attach the 2 clamps.

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

    2. Attach the 3 wire harness clamps and connect the 2 revolution sensor connectors and transmission wire connector to the continuously variable transaxle.

    3. Connect the park/neutral position switch connector to the continuously variable transaxle.

    4. Attach the 4 wire harness clamps and connect the oil pressure sensor connector, revolution sensor connector to the continuously variable transaxle.

  15. INSTALL WATER BY-PASS HOSE ASSEMBLY


    1. Engage the clamp and install the water bypass hoses.

    2. Install the water bypass hoses onto the oil cooler with the 2 hose clamps.

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  17. RESET MEMORY (CVT initialization)

    Note

    Perform reset memory (CVT initialization) when replacing the CVT Click here.