CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY INSTALLATION

INSPECT TORQUE CONVERTER ASSEMBLY

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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 attach the CVT oil pump type T oil seal by pressing it onto the installation surface of the oil pump housing manually.

*a	0 to 0.5 mm (0 to 0.0196 in.)

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

Using SST, drive the CVT oil pump type T oil seal in evenly, as far as the side surface of the oil pump housing.

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.
Tip:
The oil seal should be driven in between 0 and 0.5 mm (0 and 0.0196 in.) as measured from the side surface of the oil pump housing.

INSTALL TORQUE CONVERTER ASSEMBLY

*a	Matchmark
*b	Groove

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

*a	Matchmark
*b	Key

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

*a	Matchmark

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

Note:

Install the torque converter horizontally to the input shaft.

*1	CVT Oil Pump Type T Oil Seal
*a	Matchmark

Rotate the torque converter and mesh the splines of the stator shaft with the stator splines.

Tip:

Rotate the torque converter approximately 180°.

Note:

Do not damage the oil seal.
Install the torque converter horizontally to the input shaft.

*1	CVT Oil Pump Type T Oil Seal
*a	Matchmark

Rotate the torque converter again, align the matchmark on the housing with the one on the torque converter 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 horizontally to the input shaft.

Clean the torque converter set bolt holes.

*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 surface of the drive plate*2. (#)

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 step (#)).

Standard

A + 1 mm (0.0394 in.) or more

Note:
Subtract the thickness of the straightedge from the measured value to gain dimension "B".

INSTALL WIRE HARNESS CLAMP BRACKET

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

for Bolt A

7.7 N*m

79 kgf*cm

68 in.*lbf

for Bolt B

12 N*m

122 kgf*cm

9 ft.*lbf

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.

12 N*m

122 kgf*cm

9 ft.*lbf

INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

Transfer Side:
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Clean the bolt holes.

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.

*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.

Note:

Install the sealed side of the stud bolt to the transaxle assembly.

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

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 automatic transaxle assembly.

Tip:
Stud bolt length:

Stud bolt A: 69 mm (2.72 in.)

Stud bolt B: 47 mm (1.85 in.)

INSTALL TRANSFER ASSEMBLY

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INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

*1	Torque Converter Assembly Centerpiece
*2	Crankshaft

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.)
Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before transaxle installation.
Maintain the engine and continuously variable transaxle assembly in a horizontal position, align the knock pins with each hole on the continuously variable transaxle assembly and install the continuously variable transaxle assembly with the 8 bolts shown in the illustration.

for bolt A

38 N*m

387 kgf*cm

28 ft.*lbf

for bolt B

40 N*m

408 kgf*cm

30 ft.*lbf

Tip:
Bolt A: Install from the continuously variable transaxle assembly side.

Bolt B: Install from the engine assembly side.

CAUTION:
Make sure that the torque converter rotates.

INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

*a	Adhesive

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

Adhesive

Toyota Genuine Adhesive 1324,

Three Bond 1324 or equivalent
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 bolt with a wrench.

41 N*m

418 kgf*cm

30 ft.*lbf

Note:
Install the black bolt first, and then the remaining 5 silver bolts.
Install the flywheel housing under cover.

INSTALL ENGINE WIRE

for Front Side:
Attach the 3 wire harness clamps and connect the 3 revolution sensor connectors, park/neutral position sensor connector and transmission wire connector to the continuously variable transaxle assembly.

for Rear Side:

Attach the 2 wire harness clamps and connect the oil pressure sensor connector to the continuously variable transaxle assembly.

*a	for Front Side	*b	for Rear Side

INSTALL GROUND CABLE

Install the ground cable to the continuously variable transaxle assembly with the bolt and attach the clamp.

8.4 N*m

86 kgf*cm

74 in.*lbf

INSTALL REAR ENGINE MOUNTING BRACKET

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

45 N*m

459 kgf*cm

33 ft.*lbf

INSTALL FRONT ENGINE MOUNTING BRACKET

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

64 N*m

653 kgf*cm

47 ft.*lbf

INSTALL ENGINE MOUNTING BRACKET LH

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

64 N*m

653 kgf*cm

47 ft.*lbf

INSTALL STARTER ASSEMBLY

for 1.0 kW Type:
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for 1.3 kW Type:
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CONNECT WATER BY-PASS HOSE

*a	Yellow Paint Mark

Connect the 2 water by-pass hoses to the oil cooler, and slide the clamp to secure it.

Note:
Make sure the pinching portion of each clip is facing the directions shown in the illustration and the paint marks are aligned as shown in the illustration.

INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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RESET MEMORY

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