Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM100000001MU1Q
Model Year Start: 2020 Model: Corolla Hatchback Prod Date Range: [09/2019 - 04/2020]
Title: K120 / K121 (CVT): CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY: INSTALLATION; 2020 MY Corolla Corolla Hatchback [09/2019 - 04/2020]

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 BREATHER PLUG SUB-ASSEMBLY

HINT:

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

(a) Coat a new O-ring with Toyota Genuine CVT fluid FE and install it to the breather plug.

NOTICE:

Ensure that the O-ring is not twisted.

(b) Install the breather plug cap to the breather plug.

(c) Install the breather plug sub-assembly to the continuously variable transaxle assembly.

NOTICE:

Be careful not to damage the O-ring.

2. INSTALL TRANSMISSION CASE PLUG ASSEMBLY

(a) Coat a new O-ring with Toyota Genuine CVT fluid FE and install it to the transmission case plug assembly.

NOTICE:

Ensure that the O-ring is not twisted.

(b) Install the transmission case plug assembly to the continuously variable transaxle assembly.

NOTICE:

Be careful not to damage the O-ring.

3. 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}

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:

19 N·m {194 kgf·cm, 14 ft·lbf}

HINT:

Provisionally set the No. 1 water hose clamp bracket onto the continuously variable transaxle assembly when installing it.

5. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 5 wire harness clamp brackets to the continuously variable transaxle assembly with the 5 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

6. INSTALL ENGINE MOUNTING BRACKET LH

(a) Install the engine mounting bracket LH to the continuously variable transaxle assembly with the 3 bolts in the order shown in the illustration.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

*a

Temporarily Tighten

7. INSTALL ENGINE MOUNTING STAY LH

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

Torque:

41 N·m {418 kgf·cm, 30 ft·lbf}

*a

Temporarily Tighten

8. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Install the No. 3 water by-pass pipe sub-assembly to the continuously variable transaxle assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

9. INSTALL NO. 3 WATER BY-PASS HOSE

(a) Install the No. 3 water by-pass hose to the No. 3 water by-pass pipe sub-assembly and slide the clip to secure it.

*a

2 to 7 mm (0.0787 to 0.276 in.)

*b

Paint Mark

*c

45° (Claw of Clip Location)

-

-

NOTICE:

  • Make sure to slide the No. 3 water by-pass hose until it contacts the hose stopper of the No. 3 water by-pass pipe sub-assembly.
  • Make sure to align the paint mark of the No. 3 water by-pass hose with the paint mark of the No. 3 water by-pass pipe sub-assembly.
  • Make sure that the claws of the clip are within the location shown in the illustration.

10. INSTALL NO. 4 WATER BY-PASS HOSE

(a) Install the No. 4 water by-pass hose to the transmission oil cooler and slide the clip to secure it.

*a

2 to 12 mm (0.0787 to 0.472 in.)

*b

Paint Mark

*c

60° (Claw of Clip Location)

-

-

NOTICE:

  • Make sure to slide the No. 4 water by-pass hose until it contacts the hose stopper of the transmission oil cooler.
  • Make sure to align the paint mark of the No. 4 water by-pass hose with the paint mark of the transmission oil cooler.
  • Make sure that the claws of the clip are within the location shown in the illustration.

(b) Engage the hose clamp to connect the No. 4 water by-pass hose to the No. 1 water hose clamp bracket.

11. INSTALL FLOW SHUTTING VALVE (WATER VALVE)

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12. INSTALL TRANSAXLE HOUSING 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 transaxle housing type T oil seal.

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

NOTICE:

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

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

SST: 09309-36010

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

Standard Depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

NOTICE:

  • Drive the transaxle housing type T oil seal in gradually, while visually checking that it is even.
  • After installation, confirm that the transaxle housing type T oil seal has been driven in until it is even with the side surface of the transaxle housing.
  • Wipe any extra grease off with your hand.

*a

Depth

13. INSTALL TORQUE CONVERTER ASSEMBLY

(a) Set the key at the top of the drive sprocket and put a matchmark on the transaxle housing.

*a

Matchmark

*b

Key

(b) Apply MP grease to place a matchmark on the torque converter assembly so that the position of its groove is clearly indicated.

*a

Groove

*b

Matchmark

MP Grease

(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 transaxle housing type T oil seal.

*1

Transaxle Housing 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 push the torque converter assembly excessively when rotating it.
  • Do not damage the transaxle housing type T oil seal.

*1

Transaxle Housing 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 groove of the torque converter assembly into the key of the drive sprocket.

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 transaxle housing type T oil seal.

*1

Transaxle Housing 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.

NOTICE:

Make sure to deduct the thickness of the straightedge.

*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.

14. SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

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

NOTICE:

  • Adjust the attachment of the transmission jack to securely fix the continuously variable transaxle assembly to the transmission jack.
  • Using a lashing belt or a rope, fix the continuously variable transaxle assembly to the transmission jack.

15. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

(a) Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

*1

Crankshaft

*2

Torque Converter Assembly Centerpiece

Clutch Spline Grease

Clutch Spline Grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum Grease Amount

Approximately 1 g (0.0353 oz)

(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 8 bolts.

Torque:

Bolt (A) :

64 N·m {653 kgf·cm, 47 ft·lbf}

Bolt (B) :

25 N·m {255 kgf·cm, 18 ft·lbf}

Bolt (C) :

46 N·m {469 kgf·cm, 34 ft·lbf}

Bolt Length:

Bolt

Length

(A)

50 mm (1.97 in.)

(B)

35 mm (1.38 in.)

(C)

45 mm (1.77 in.)

NOTICE:

  • 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.

HINT:

  • Bolt (A), (B): Install from the continuously variable transaxle assembly side.
  • Bolt (C): Install from the engine assembly side.

16. INSTALL ENGINE MOUNTING INSULATOR LH

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

*a

Torque Wrench Fulcrum Length

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

SST: 09961-00950

Torque:

Specified Tightening Torque :

42 N·m {428 kgf·cm, 31 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 4 bolts and nut in the order of (B), (C), (D), (A) and (E).

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

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  • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

    22.9 N*m (234 kgf*cm, 17 ft.*lbf)

(c) Install the engine mounting insulator LH to the engine mounting stay LH with the 3 bolts, through bolt and nut in the order shown in the illustration.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

NOTICE:

  • While holding the nut in place, tighten the through bolt.
  • Temporarily tighten the bolt (A), and then fully tighten the 4 bolts and nut in the order of (B), (C), (D) and (A).

17. 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:

Make sure to install the 6 drive plate and torque converter assembly setting bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

*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:

41 N·m {418 kgf·cm, 30 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.

18. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Engage the 2 claws and guide to install the flywheel housing under cover to the cylinder block sub-assembly.

Install in this Direction

19. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

(a) Install the drive shaft heat insulator sub-assembly to the cylinder block sub-assembly with the 3 bolts in the order shown in the illustration.

Torque:

17.6 N·m {179 kgf·cm, 13 ft·lbf}

*a

Temporarily Tighten

20. INSTALL MANIFOLD STAY

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21. INSTALL NO. 2 ENGINE MOVING CONTROL ROD

(a) Install the No. 2 engine moving control rod to the continuously variable transaxle assembly with the 5 bolts in the order shown in the illustration.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

*a

Temporarily Tighten

22. 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.

CAUTION:

  • The front suspension crossmember sub-assembly is a very heavy component. Make sure that it is supported securely.
  • If the front suspension crossmember sub-assembly is not securely supported, it may drop, resulting in serious injury.

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 engine moving control rod with the bolt.

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

23. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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24. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

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

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26. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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27. INSTALL COLUMN HOLE COVER SILENCER SHEET

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28. 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.

29. REMOVE ENGINE HANGER

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30. INSTALL FUEL DELIVERY GUARD

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31. CONNECT WATER BY-PASS HOSE ASSEMBLY

(a) Connect the water by-pass hose assembly to the No. 3 water by-pass pipe sub-assembly and slide the clip to secure it.

*a

2 to 13 mm (0.0787 to 0.512 in.)

*b

Paint Mark

*c

60° (Claw of Clip Location)

-

-

NOTICE:

  • Make sure to slide the water by-pass hose assembly until it contacts the hose stopper of the No. 3 water by-pass pipe sub-assembly.
  • Make sure to align the paint mark of the water by-pass hose assembly with the paint mark of the No. 3 water by-pass pipe sub-assembly.
  • Make sure that the claws of the clip are within the location shown in the illustration.

32. CONNECT INLET WATER HOSE

(a) Connect the inlet water hose to the transmission oil cooler and slide the clip to secure it.

*a

2 to 12 mm (0.0787 to 0.472 in.)

*b

Paint Mark

*c

60° (Claw of Clip Location)

-

-

NOTICE:

  • Make sure to slide the inlet water hose until it contacts the hose stopper of the transmission oil cooler.
  • Make sure to align the paint mark of the inlet water hose with the paint mark of the transmission oil cooler.
  • Make sure that the claws of the clip are within the location shown in the illustration.

33. INSTALL TCM

NOTICE:

To prevent coolant from entering the TCM through its connector portion, be sure to connect all of the coolant system hoses before installing the TCM.

(a) Install the TCM to the continuously variable transaxle assembly with the 2 bolts.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

34. CONNECT ENGINE WIRE

(a) Engage the 3 clamps to connect the engine wire to the wire harness clamp bracket.

(b) Engage the 4 clamps to connect the engine wire to the wire harness clamp bracket and No. 1 transmission control cable bracket.

*a

Transmission Wire Connector

*b

Shift Stroke Sensor Connector

*c

Park/Neutral Position Switch Connector

*d

Transmission Revolution Sensor (NOUT) Connector

*e

TCM Connector

*f

Transmission Revolution Sensor (NSS) Connector

*g

Oil Pressure Sensor Connector

*h

Transmission Revolution Sensor (NT) Connector

Install in this Direction

-

-

(c) Connect the engine wire to the continuously variable transaxle assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 89 in·lbf}

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

(e) Connect the oil pressure sensor connector.

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

(g) Connect the TCM connector and rotate the lever and engage the claw.

HINT:

Rotate the lever until the claw of the TCM connector makes a click sound.

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

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

(j) Connect the shift stroke sensor connector.

(k) Connect the transmission wire connector and rotate the lever and engage the claw.

HINT:

Rotate the lever until the claw of the transmission wire connector makes a click sound.

(l) Engage the 3 clamps to connect the engine wire to the No. 1 water hose clamp bracket and wire harness clamp bracket.

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

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(n) Connect the flow shutting valve (water valve) connector.

(o) Connect the engine coolant temperature sensor connector.

(p) Connect the camshaft position sensor connector.

(q) Connect the engine wire to the engine assembly with the bolt and 2 nuts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

35. CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

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36. INSTALL STARTER ASSEMBLY

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

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38. INSTALL FRONT FLOOR CENTER BRACE

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39. INSTALL FRONT FLOOR COVER LH

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40. INSTALL FRONT FLOOR COVER RH

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41. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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42. INSTALL BATTERY

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43. INSTALL ECM

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44. 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}

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

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46. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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47. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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48. ADD ENGINE COOLANT (for Fully Sealed Type)

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49. ADD ENGINE COOLANT (for Non-Fully Sealed Type)

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50. ADJUST CONTINUOUSLY VARIABLE TRANSAXLE FLUID

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51. INSPECT SHIFT LEVER POSITION

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52. ADJUST SHIFT LEVER POSITION (for TMC Made)

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53. ADJUST SHIFT LEVER POSITION (for TMMMS Made)

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54. INSPECT FOR COOLANT LEAK (for Fully Sealed Type)

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55. INSPECT FOR COOLANT LEAK (for Non-Fully Sealed Type)

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56. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL (for Fully Sealed Type)

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57. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL (for Non-fully sealed Type)

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58. INSPECT FOR EXHAUST GAS LEAK

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59. RESET MEMORY

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