INSTALLATION

PROCEDURE

1. INSTALL CVT OIL PUMP TYPE T OIL SEAL

(a) 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.

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

NOTICE:

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

(c) Clean the CVT oil pump type T oil seal contact surface of SST and the area around it.

SST: 09309-36010

(d) 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.) NOTICE: 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.

*a Depth

2. INSTALL STRAIGHT SCREW PLUG

HINT:

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

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

Torque:

16.2 N·m {165 kgf·cm, 12 ft·lbf}

3. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 3 wire harness clamp brackets to the continuously variable transaxle assembly with the 3 bolts.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

4. INSTALL NO. 1 WATER HOSE CLAMP BRACKET

(a) Install the No. 1 water hose clamp bracket to the continuously variable transaxle assembly with the bolt.

Torque:

14 N·m {143 kgf·cm, 10 ft·lbf}

(b) Install the hose clamp to the No. 1 water hose clamp bracket.

(c) Install the clamp to the No. 1 water hose clamp bracket.

5. INSTALL TORQUE CONVERTER ASSEMBLY

(a) 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. NOTICE: 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 Matchmark *b Wide Groove *c Narrow Groove

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

*a Key *b Matchmark

(c) 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. NOTICE: 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

(d) Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly. NOTICE: 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

(e) 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. NOTICE: 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.

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

(f) Clean the drive plate and torque converter assembly setting bolt holes.

(g) 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.

*a Engine Assembly Surface *b Drive Plate Surface

(h) 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 NOTICE: 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.

6. SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

(a) Using a transmission jack, support the continuously variable transaxle assembly.

7. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

(a) 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	Crankshaft
*2	Torque Converter Assembly Centerpiece
	Clutch Spline Grease

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

*1 Knock Pin

(c) 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}

8. INSTALL ENGINE MOUNTING BRACKET LH

(a) Install the engine mounting bracket LH to the continuously variable transaxle assembly with the 3 bolts. Torque: 41 N·m {418 kgf·cm, 30 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A)

9. INSTALL ENGINE MOUNTING STAY LH

(a) Install the engine mounting stay LH to the continuously variable transaxle assembly and engine mounting bracket LH with the 2 bolts. Torque: 32 N·m {326 kgf·cm, 24 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (A)

10. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Temporarily install the engine mounting insulator LH to the vehicle body.

(b) Install the 4 bolts and nut in the order shown in the illustration.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

HINT:

Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (D) → Fully tighten bolt (A) → Fully tighten nut (E)

(c) Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

NOTICE:

While holding the nut in place, tighten the bolt.

11. INSTALL NO. 2 ENGINE MOVING CONTROL ROD

(a) Install the No. 2 engine moving control rod to the continuously variable transaxle assembly with the 4 bolts. Torque: 44 N·m {449 kgf·cm, 32 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (D) → Fully tighten bolt (A)

12. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Slowly jack up the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.

NOTICE:

Use attachments to keep the front suspension crossmember sub-assembly level.

(b) Install the front suspension crossmember sub-assembly to the vehicle body with the 4 bolts.

Torque:

141 N·m {1438 kgf·cm, 104 ft·lbf}

(c) Lower the engine lifter.

(d) Install the No. 2 engine moving control rod with the bolt.

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

13. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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14. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

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15. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

(a) Clean the threads of the 6 drive plate and torque converter assembly setting bolts.

(b) 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 NOTICE: 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.

*a Adhesive

(c) 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}

NOTICE:

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.

16. INSTALL FLYWHEEL HOUSING UNDER COVER

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17. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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18. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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19. INSTALL COLUMN HOLE COVER SILENCER SHEET

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20. REMOVE ENGINE SUPPORT BRIDGE

(a) Remove SST from the vehicle body.

NOTICE:

Prevent SST from contacting the vehicle body or windshield glass.

(b) Connect the inlet hose to the vehicle body with the clip.

21. CONNECT NO. 3 RADIATOR HOSE

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22. REMOVE ENGINE HANGERS

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23. INSTALL WIRE HARNESS CLAMP BRACKET

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24. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) 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}

25. INSTALL STARTER ASSEMBLY (for DENSO Made)

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26. CONNECT WATER BY-PASS HOSE

(a) Engage the clamp to install the water by-pass hose to the continuously variable transaxle assembly.

(b) Connect the water by-pass hose to the transmission oil cooler and slide the 2 clips to secure them.

NOTICE:

Fully insert the water by-pass hose to the 2nd rib on each oil cooler pipe.

27. CONNECT ENGINE WIRE

(a) Engage the 3 clamps to connect the engine wire to the front suspension crossmember sub-assembly.

(b) Engage the 5 clamps.

(c) Connect the oil pressure sensor connector.

(d) Connect the transmission revolution sensor (NOUT) connector.

(e) Connect the park/neutral position switch connector.

(f) Connect the transmission revolution sensor (NIN) connector.

(g) Connect the transmission wire connector.

(h) Connect the engine wire to the continuously variable transaxle assembly with the bolt.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

(i) Connect the engine wire to the No. 1 transmission control cable bracket with the bolt.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

28. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

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29. CONNECT NO. 1 BREATHER PLUG (CVT)

(a) Connect the No. 1 breather plug (CVT) to the clamp.

30. CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

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31. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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32. CONNECT ENGINE WIRE

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33. INSTALL BATTERY

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34. INSTALL ECM

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35. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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36. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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37. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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38. INSTALL INLET NO. 1 AIR CLEANER

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39. INSTALL RADIATOR SUPPORT OPENING COVER

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40. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) Remove the 4 nuts.

(b) Install the outer cowl top panel sub-assembly with the 9 bolts and 4 nuts.

Torque:

Bolt :

12 N·m {122 kgf·cm, 9 ft·lbf}

Nut :

50 N·m {510 kgf·cm, 37 ft·lbf}

41. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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42. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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43. ADD ENGINE COOLANT

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44. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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45. ADJUST CONTINUOUSLY VARIABLE TRANSAXLE FLUID

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46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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47. INSPECT SHIFT LEVER POSITION

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48. ADJUST SHIFT LEVER POSITION

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49. INSPECT FOR COOLANT LEAK

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50. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL

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51. INSPECT FOR EXHAUST GAS LEAK

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52. RESET MEMORY

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