Installation [06/2015 - ]: Procedure

HINT: 

Perform this procedure only when replacement of the No. 1 breather plug (CVT) is necessary.

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

HINT: 

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

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

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. 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) 

2. Install the water by-pass hose clamp bracket to the continuously variable transaxle assembly with the bolt.

   Torque: 18.5 N*m (189 kgf*cm, 14 ft.*lbf) 

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

1. Clean the bolts and installation holes in the engine mounting bracket LH.
2. Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Adhesive

   Adhesive

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   NOTE:

   In order to ensure proper installation of the 3 bolts, apply adhesive to the 3 bolts and install them within 10 minutes of adhesive application.

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

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

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

   Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Bolt Length

   Bolt Length 25 mm (0.984 in.) 

   Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

   Bolt Length 22 mm (0.866 in.) 

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

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) 

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

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

3. Clean the CVT oil pump type T oil seal contact surface of SST and the area around it.
   • SST: 09309-36010 
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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Depth

   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.

   HINT: 

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

1. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Matchmark
   *b	Wide Groove
   *c	Narrow 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.
2. Place a matchmark on the torque converter assembly so that the position of its key is clearly indicated.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Key
   *b	Matchmark

3. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Type A
   *B	for Type B
   *1	CVT Oil Pump Type T Oil Seal
   *2	Torque Converter Assembly Centerpiece
   *a	Matchmark

   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.

   HINT: 

   • There are 2 different types of torque converter assembly centerpiece.
   • Either type A or B is installed.
4. Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Type A
   *B	for Type B
   *1	CVT Oil Pump Type T Oil Seal
   *2	Torque Converter Assembly Centerpiece
   *a	Matchmark

   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.

   HINT: 

   • There are 2 different types of torque converter assembly centerpiece.
   • Either type A or B is installed.
5. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Type A
   *B	for Type B
   *1	CVT Oil Pump Type T Oil Seal
   *2	Torque Converter Assembly Centerpiece
   *a	Matchmark

   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.

   HINT: 

   • There are 2 different types of torque converter assembly centerpiece.
   • Either type A or B is installed.
6. Clean the drive plate and torque converter assembly setting bolt holes.
7. 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Engine Surface
   *b	Drive Plate Surface

8. Using a vernier caliper and straightedge, measure the dimension (B) shown in the illustration and check that dimension (B) is more than dimension (A), which was measured in the previous step.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Type A
   *B	for Type B
   *1	Torque Converter Assembly Centerpiece

   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.

   HINT: 

   • There are 2 different types of torque converter assembly centerpiece.
   • Either type A or B is installed.

1. Using a transmission jack attachment, set the continuously variable transaxle assembly on a transmission jack.
   NOTE:

   • Secure the continuously variable transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.
   • To prevent the transaxle oil (CVT) pan sub-assembly from deforming, do not place any attachments under the transaxle oil (CVT) pan sub-assembly.
   • Hold the engine assembly with a suitable adapter, such as a rope, during the operation.
2. Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Type A
   *B	for Type B
   *1	Crankshaft
   *2	Torque Converter Assembly Centerpiece

   Clutch Spline Grease

   Toyota Genuine Clutch Spline Grease or equivalent

   Maximum Grease Amount 

   Approximately 1 g (0.0353 oz)

   HINT: 

   • There are 2 different types of torque converter assembly centerpiece.
   • Either type A or B is installed.
3. Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Knock Pin

4. 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 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.

   HINT: 

   • Bolt (A): Install from continuously variable transaxle assembly side
   • Bolt (B): Install from engine assembly side

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 12

1. Engage the 7 clamps.
2. Connect the transmission wire connector.
3. Connect the transmission revolution sensor (NIN) connector.
4. Connect the park/neutral position switch assembly connector.
5. Connect the oil pressure sensor connector.
6. Connect the transmission revolution sensor (NOUT) connector.

1. Install the No. 5 water by-pass hose to the transmission oil cooler and engine assembly and slide the 3 clips to secure it.
   NOTE:

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

2. Engage the clamp.

Refer to PROCEDURE - Step 18

Refer to PROCEDURE - Step 19

Refer to PROCEDURE - Step 20

Refer to PROCEDURE - Step 21

Refer to PROCEDURE - Step 22

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 8

Refer to PROCEDURE - Step 9

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Adhesive

   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.

3. 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.

Refer to INSTALLATION [06/2015 - ]

Refer to INITIALIZATION [06/2015 - ]