CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY(When Using the Engine Support Bridge)

INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

Tech Tips

Perform this procedure only when replacement of the transmission breather hose sub-assembly is necessary.

Apply Toyota Genuine CVT fluid FE to a new O-ring, and install it to the No. 2 breather plug (CVT).

Note

Be careful not to damage or twist the O-ring.
Install the No. 1 breather plug (CVT) and No. 2 breather plug (CVT) to the breather plug hose.
Install the transmission breather hose sub-assembly to the continuously variable transaxle assembly.

INSTALL STRAIGHT SCREW PLUG

Tech Tips

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

Install the straight screw plug and a new gasket to the continuously variable transaxle assembly.

Torque:

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

INSTALL NO. 1 HEATER BRACKET SUB-ASSEMBLY

Install the No. 1 heater bracket sub-assembly to the continuously variable transaxle assembly with the bolt.

Torque:

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Install the clamp to the No. 1 heater bracket sub-assembly.
Install the No. 1 breather plug (CVT) to the clamp.

INSTALL WIRE HARNESS CLAMP BRACKET

Install the 4 wire harness clamp brackets to the continuously variable transaxle assembly with the 4 bolts.

Torque:

12.5 N*m { 127 kgf*cm, 9 ft.*lbf }

INSTALL CVT OIL PUMP TYPE T OIL SEAL

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.
Temporarily install the CVT oil pump type T oil seal by pressing it to the installation surface of the oil pump housing by hand.

Note

Be sure to install the CVT oil pump type T oil seal in the correct direction.
Clean the CVT oil pump type T oil seal contact surface of SST and the area around it.

SST

09309-36010
*a Depth

Using SST and a hammer, drive the CVT oil pump type T oil seal in evenly, until it is even with the side surface of the oil pump housing.

Standard Depth

0 to 0.5 mm (0 to 0.0197 in.)
Note
- Drive the CVT oil pump type T oil seal in gradually, while visually checking that it is even.
- After installation, confirm that the CVT oil pump type T 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.

Standard Depth
0 to 0.5 mm (0 to 0.0197 in.)

INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

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INSTALL TRANSFER ASSEMBLY

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INSTALL TORQUE CONVERTER ASSEMBLY

*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 transaxle housing to indicate the position of the groove.

Note

Place the matchmark on the transaxle housing to indicate the position of the wide groove.
The matchmark position must be correct to prevent damage.

*a Key

*b Matchmark

Place a matchmark on the torque converter assembly so that the position of its key is clearly indicated.
*1 CVT Oil Pump Type T Oil Seal

*a Matchmark

Align the matchmark on the transaxle 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.
- Do not damage the CVT oil pump type T oil seal.
*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
- Install the torque converter assembly to the input shaft while keeping it horizontal.
- Do not damage the CVT oil pump type T oil seal.
*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 transaxle housing and insert the key of the torque converter assembly into the groove of the front oil pump drive gear.
Note
- Install the torque converter assembly to the input shaft while keeping it horizontal.
- Do not push the torque converter assembly excessively when rotating it.
- Do not damage the CVT oil pump type T oil seal.
Clean the drive plate and torque converter assembly setting bolt holes.
*a Engine Assembly Surface

*b Drive Plate Surface

Using a vernier caliper and straightedge, measure the dimension (A) between the continuously variable transaxle assembly contact surface of the engine*a and the torque converter assembly contact surfaces of the drive plate*b.
Using a vernier caliper and straightedge, measure the dimension (B) shown in the illustration and check that the dimension (B) is more than the dimension (A), which was measured in the previous step.

Standard

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.

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

SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

Using a transmission jack, support the continuously variable transaxle assembly.
Note
- Adjust the attachment of the transmission jack to securely fix the continuously variable transaxle assembly to the transmission jack.
- To prevent the transaxle oil (CVT) pan sub-assembly from deforming, do not place any attachments under the transaxle oil (CVT) pan sub-assembly of the continuously variable transaxle assembly.
- Using a lashing belt or a rope, fix the continuously variable transaxle assembly to the transmission jack.

INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

*1	Crankshaft
*2	Torque Converter Assembly Centerpiece
	Clutch Spline Grease

Apply clutch spline grease to the surface 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.)

*1 Knock Pin

Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.
Install the continuously variable transaxle assembly to the engine assembly with the 7 bolts.

Torque:

29.5 N*m { 301 kgf*cm, 22 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 (A): Install from continuously variable transaxle assembly side
- Bolt (B): Install from engine assembly side

INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

*a Temporarily Tighten

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

Torque:

41 N*m { 418 kgf*cm, 30 ft.*lbf }

INSTALL ENGINE MOUNTING STAY LH

*a Temporarily Tighten

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

Torque:

32 N*m { 326 kgf*cm, 24 ft.*lbf }

INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR

*a Temporarily Tighten

Temporarily install the transverse engine engine mounting insulator to the vehicle body with the nut and 4 bolts.
Fully tighten the nut and 4 bolts in the order shown in the illustration.

Torque:

42 N*m { 428 kgf*cm, 31 ft.*lbf }
Install the transverse engine engine mounting insulator to the transverse engine engine mounting bracket with the bolt and nut.

Torque:

44 N*m { 449 kgf*cm, 32 ft.*lbf }

Note

Turn the bolt while holding the nut.

INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Clean the threads of the 6 drive plate and torque converter assembly setting bolts.
*a Adhesive

Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter assembly setting bolts.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Note

To prevent contamination by foreign matter, install immediately after applying adhesive.
Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

Torque:

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

Note

First install the black colored drive plate and torque converter assembly setting bolt, and then the remaining 5 silver colored drive plate and torque converter assembly setting bolts.

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

INSTALL FLYWHEEL HOUSING UNDER COVER

Install the flywheel housing under cover to the stiffening crankcase assembly.

INSTALL FLYWHEEL HOUSING SIDE COVER

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INSTALL STARTER ASSEMBLY (for Valeo Made Cold Area Specification Vehicles)

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INSTALL STARTER ASSEMBLY (for Valeo Made except Cold Area Specification Vehicles)

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INSTALL STARTER ASSEMBLY (for Denso Made without Stop and Start System)

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INSTALL NO. 2 ENGINE MOVING CONTROL ROD

*a Temporarily Tighten

Install the No. 2 engine moving control rod to the continuously variable transaxle assembly with the 4 bolts in the order shown in the illustration.

Torque:

44 N*m { 449 kgf*cm, 32 ft.*lbf }

INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

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REMOVE ENGINE SUPPORT BRIDGE

Remove SST from the vehicle body.

Note

Prevent SST from contacting the vehicle body or windshield glass.
Install the neck from the windshield washer jar assembly with the clip.

REMOVE ENGINE HANGER

Remove the 2 bolts and No. 2 engine hanger from the cylinder head.
Remove the 2 bolts and No. 1 engine hanger from the cylinder head.
Connect the No. 2 earth wire to the engine mounting insulator sub-assembly RH with the bolt.

Torque:

10.5 N*m { 107 kgf*cm, 8 ft.*lbf }
Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

Torque:

39 N*m { 398 kgf*cm, 29 ft.*lbf }
Install the engine wire to the wire harness clamp bracket with the nut.

Torque:

10 N*m { 102 kgf*cm, 7 ft.*lbf }
Engage the 3 clamps with the wire harness clamp bracket.

INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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INSTALL FRONT DRIVE SHAFT ASSEMBLIES (for TMC Made)

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INSTALL FRONT DRIVE SHAFT ASSEMBLIES (for TMMT Made)

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INSTALL FRONT EXHAUST PIPE ASSEMBLY

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INSTALL NO. 2 CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

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INSTALL FRONT FLOOR CENTER BRACE

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INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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INSTALL COLUMN HOLE COVER SILENCER SHEET

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INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

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 }

CONNECT WATER HOSE

Engage the 2 clamps to install the water hose to the continuously variable transaxle assembly.
Connect the water hose to the transmission oil cooler and slide the 2 hose clips to secure them.

CONNECT ENGINE WIRE

Engage the 7 clamps to connect the engine wire to the continuously variable transaxle assembly.

*1	Park/Neutral Position Switch Connector	*2	Transmission Wire Connector
*3	Transmission Revolution Sensor (NIN) Connector	*4	Transmission Revolution Sensor (NOUT) Connector
*5	Oil Pressure Sensor Connector	-	-

Connect the oil pressure sensor connector.
Connect the transmission revolution sensor (NOUT) connector.
Connect the park/neutral position switch connector.
Connect the transmission revolution sensor (NIN) connector.
Connect the transmission wire connector.
Connect the engine wire to the continuously variable transaxle assembly with the bolt.

Torque:

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

CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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INSTALL BATTERY CLAMP SUB-ASSEMBLY

Install the air battery clamp sub-assembly to the vehicle with the 3 bolts.

Torque:

15.4 N*m { 157 kgf*cm, 11 ft.*lbf }
Engage the clamp to connect the engine wire to the battery clamp sub-assembly.
Connect the engine wire to the battery clamp sub-assembly with the bolt and nut.

Torque:

7.0 N*m { 71 kgf*cm, 62 in.*lbf }