CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with continuously variable transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE


  1. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

    Transfer Side
    Click here Click here

    1. Clean the bolt holes.

    2. Apply adhesive 1324 to 2 or 3 threads on one half of a new transfer and transaxle setting stud bolt A as shown in the illustration.

      B008H1CC03
      *a Adhesive 1324 *b Sealant
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Do not apply adhesive 1324 to the ends of the stud bolt.

      • Install the stud bolt immediately after applying adhesive to prevent the adherence of foreign matter.

      • Install to continuously variable transaxle assembly applying the sealant of the stud bolt.

    3. Install the 2 new transfer and transaxle setting stud bolts to the transaxle case positions shown in the illustration.

      Torque:
      39.2 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Install the stud bolt so that the side that has sealant and adhesive is facing the continuously variable transaxle assembly.

      Tech Tips

      Stud bolt length

      • Stud bolt A: 73 mm (2.87 in.)

      • Stud bolt B: 47 mm (1.85 in.)

  2. INSTALL AUTOMATIC TRANSMISSION CASE COVER


    1. Install the automatic transmission case cover to the continuously variable transaxle assembly with the 2 clips.

  3. INSTALL BREATHER PLUG HOSE

    Tech Tips

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


    1. B008H0VC04
      *1 Breather Plug
      *2 Breather Plug (Continuously Variable Transaxle Assembly Side)
      *3 O-ring
      *4 Breather Plug Hose

      Install a new O-ring to a new breather plug.

    2. Install the new breather plug (continuously variable transaxle assembly side) to the breather plug hose.

    3. Install the breather plug to the breather plug hose.

    4. Install the breather plug hose to the continuously variable transaxle assembly.

  4. INSTALL TRANSMISSION OIL FILLER TUBE STRAIGHT SCREW PLUG

    Tech Tips

    Perform this procedure only when replacement of the transmission oil filler tube straight screw plug is necessary.


    1. Install a new gasket and the transmission oil filler tube straight screw plug to the continuously variable transaxle assembly.

      Torque:
      16.2 N*m  { 165 kgf*cm, 12 ft.*lbf }

  5. INSTALL OIL COOLER ELBOW SUB-ASSEMBLY


    1. Install a new gasket and oil cooler elbow sub-assembly to the continuously variable transaxle assembly with the union bolt.

      Torque:
      22.6 N*m  { 230 kgf*cm, 17 ft.*lbf }

      Note


      • Make sure to insert the painted end (white) of the No. 2 transmission oil cooler hose up to the spool fitting of the oil cooler elbow sub-assembly so that the marking is facing the front of the vehicle.

      • Make sure to clean and degrease the insertion part of the No. 2 transmission oil cooler hose of the oil cooler elbow sub-assembly.

    2. Install the No. 2 transmission oil cooler hose to the oil cooler elbow sub-assembly and slide the clip to secure it.

  6. INSTALL OIL COOLER TUBE UNION


    1. Install a new O-ring to the oil cooler tube union.

    2. Install the oil cooler tube union to the continuously variable transaxle assembly.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      Note


      • Make sure to insert the painted end (white) of the No. 1 transmission oil cooler hose up to the spool fitting of the oil cooler tube union so that the marking is facing the front of the vehicle.

      • Make sure to clean and degrease the insertion part of the No. 1 transmission oil cooler hose of the oil cooler tube union.

    3. Install the No. 1 transmission oil cooler hose to the oil cooler tube union and slide the clip to secure it.

  7. INSTALL WIRE HARNESS CLAMP BRACKET

    B008IEMC04
    *1 Wire Harness Clamp Bracket *2 Water By-pass Hose Clamp
    *3 Water Hose Clamp Bracket - -

    1. Install the 3 wire harness clamp brackets to the continuously variable transaxle assembly with the 3 bolts.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

    2. Install the water by-pass hose clamp to the water hose clamp bracket.

    3. Install the water hose clamp bracket to the continuously variable transaxle assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  8. INSTALL TRANSMISSION CONTROL CABLE SUPPORT


    1. Install the transmission control cable support to the continuously variable transaxle assembly with the 2 bolts.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

  9. 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 }

    2. Connect the clamp to the No. 1 transmission control cable bracket.

  10. INSTALL CVT 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 type T oil seal.

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

      Note

      Be sure to install the CVT type T oil seal in the correct direction.

    3. Clean the CVT type T oil seal contact surface of SST and the area around it.

      SST
      09309-36010
    4. B008HT4C01
      *a 0 to 0.5 mm (0 to 0.0196 in.)

      Using SST, drive the CVT 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 0.0196 in.)

      Note


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

      • After installation, confirm that the CVT 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.

      Tech Tips

      The CVT type T oil seal should be driven in between 0 to 0.5 mm (0 to 0.0196 in.) as measured from the side surface of the oil pump housing.

  11. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B008GV7C01
      *a Matchmark

      Turn the front oil pump drive gear so that the wide groove is at the top and place a matchmark on the transaxle housing.

      Note

      Align the matchmark with the wide groove of the transaxle housing.

    2. B008GKQC01
      *a Key
      *b Matchmark

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

    3. B008H2TC01
      *1 CVT 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 type T oil seal.

    4. B008JK1C01
      *1 CVT 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 type T oil seal.

    5. B008GQNC01
      *1 CVT 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 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 type T oil seal.

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

    7. B008HSRC01
      *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 assembly*a and the torque converter assembly contact surfaces of the drive plate*b.

    8. B008H23E01

      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.

  12. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. B008J62C02
      *1 Crankshaft
      *a Torque Converter Assembly Centerpiece

      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)
    2. B008IIUE01

      Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.

    3. Install the continuously variable transaxle assembly to the engine assembly with the 8 bolts.

      Torque:
      Bolt (A)
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Bolt (B)
      40 N*m  { 408 kgf*cm, 30 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 2 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

  13. INSTALL TRANSFER ASSEMBLY

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  14. INSTALL DRIVE SHAFT BEARING BRACKET

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  15. INSTALL MANIFOLD STAY

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  16. INSTALL ENGINE MOUNTING BRACKET LH


    1. Clean and degrease the bolt holes of the continuously variable transaxle assembly.

    2. B008I4MN01

      Install the engine mounting bracket LH and engine mounting stay LH with the 6 new bolts.

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

      Note

      Tightening order: Tighten bolt (A), (B), (C), (D) → Tighten bolt (E) → Tighten bolt (F)

  17. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. B008JEIE01

      Install the front engine mounting bracket to the continuously variable transaxle assembly with the 3 bolts.

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

      Note

      Tightening order: Temporarily install bolt (A) →Tighten bolt (B) → Tighten bolt (C) → Tighten bolt (A)

  18. INSTALL REAR ENGINE MOUNTING BRACKET


    1. B008I0QE01

      Install the rear engine mounting bracket to the continuously variable transaxle assembly with the 4 bolts.

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

      Note

      Tightening order: Temporarily install bolt (A) → Tighten bolt (B) → Tighten bolt (C) → Tighten bolt (D) → Tighten bolt (A)

  19. INSTALL STARTER ASSEMBLY

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  20. CONNECT BREATHER PLUG HOSE


    1. Connect the breather plug hose to the clamp.

      Note

      Remove double clamp attached to breather hose, when the new continuously variable transaxle assembly is installed.

  21. CONNECT ENGINE WIRE


    1. B008HDD

      Connect the 2 connectors.

    2. Attach the 2 clamps.

    3. Connect the engine wire with the 2 bolts and nut.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }
    4. B008IAX

      Attach the 4 clamps to install the engine wire.

    5. Connect the engine wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    6. Connect the 5 connectors.

  22. CONNECT NO. 4 WATER BY-PASS HOSE


    1. Connect the No. 4 water by-pass hose to the oil cooler, and slide the clip to secure it.

      Note


      • Align each paint mark on the No. 4 water by-pass hose with each one on the oil cooler.

      • Fully insert the No. 4 water by-pass hose to the 2nd rib on each oil cooler pipe.

  23. CONNECT NO. 5 WATER BY-PASS HOSE


    1. Connect the No. 5 water by-pass hose to the oil cooler, and slide the clip to secure it.

      Note


      • Align each paint mark on the No. 5 water by-pass hose with each one on the oil cooler.

      • Fully insert the No. 5 water by-pass hose to the 2nd rib on each oil cooler pipe.

  24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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  25. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. Using SST, hold the crankshaft pulley.

      SST
      09213-54015
      09330-00021

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

    2. Clean the threads of the 6 drive plate and torque converter assembly setting bolts.

    3. B008I7WC45
      *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

      In order to ensure proper installation of the 6 drive plate and torque converter assembly setting bolts, apply adhesive to the 6 drive plate and torque converter assembly setting bolts and install them within 10 minutes of adhesive application.

    4. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each bolt while holding the crankshaft pulley with SST.

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

      Note

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

  26. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  27. RESET MEMORY

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