30400E
1.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 install the CVT oil pump type T oil seal by pressing it to the installation surface of the oil pump housing by hand.
Be sure to install the CVT oil pump type T oil seal in the correct direction.
Clean the CVT oil pump type T oil seal contact surface of SST and the area around it.
| *a | Depth |
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.
0 to 0.5 mm (0 to 0.0197 in.)
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.
2.INSTALL STRAIGHT SCREW PLUG
Perform this procedure only when replacement of the straight screw plug is necessary.
Install the straight screw plug and a new gasket to the continuously variable transaxle assembly.
3.INSTALL WIRE HARNESS CLAMP BRACKET
Install the 5 wire harness clamp brackets to the continuously variable transaxle assembly with the 5 bolts.
87101A
4.INSTALL NO. 1 HEATER BRACKET SUB-ASSEMBLY
Install the No. 1 heater bracket sub-assembly to the continuously variable transaxle assembly with the bolt.
Install the clamp to the No. 1 heater bracket sub-assembly.
12325A
5.INSTALL ENGINE MOUNTING BRACKET LH
Install the engine mounting bracket LH to the continuously variable transaxle assembly with the 3 bolts.
Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A)
12318
6.INSTALL ENGINE MOUNTING STAY LH
Install the engine mounting stay LH to the continuously variable transaxle assembly and engine mounting bracket LH with the 2 bolts.
Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (A)
32000A
7.INSTALL TORQUE CONVERTER ASSEMBLY
| *a | Matchmark |
| *b | Wide Groove |
| *c | Narrow Groove |
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.
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 | Key |
| *b | Matchmark |
Place a matchmark on the torque converter assembly so that the position of its key is clearly indicated.
| *1 | CVT Oil Pump 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.
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 |
Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly.
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 |
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.
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.
Clean the drive plate and torque converter assembly setting bolt holes.
| *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*a and the torque converter assembly contact surfaces of the drive plate*b.
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.
B = A + 1 mm (0.0394 in.) or more
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.
30400
8.SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY
Using a transmission jack, support the continuously variable transaxle assembly.
Adjust the attachment of the transmission jack to securely fix the continuously variable transaxle assembly to the transmission jack.
To prevent the transaxle oil (CVT) pan sub-assembly from deforming, do not place any attachments under the transaxle oil (CVT) pan sub-assembly of the continuously variable transaxle assembly.
Using a lashing belt or a rope, fix the continuously variable transaxle assembly to the transmission jack.
30400
9.INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY
| *1 | Crankshaft |
| *a | Torque Converter Assembly Centerpiece |
|
Clutch Spline Grease |
Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.
Toyota Genuine Clutch Spline Grease or equivalent
Approximately 1 g (0.0353 oz)
| *1 | Knock Pin |
Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.
Install the continuously variable transaxle assembly to the engine assembly with the 7 bolts.
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.
Bolt (A): Install from the continuously variable transaxle assembly side.
Bolt (B): Install from the engine assembly side.
12372A
10.INSTALL ENGINE MOUNTING INSULATOR LH
Temporarily install the engine mounting insulator LH to the vehicle body.
Install the 4 bolts and nut in the order shown in the illustration.
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)
Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.
While holding the nut in place, tighten the bolt.
12364B
11.INSTALL NO. 2 ENGINE MOVING CONTROL ROD
Install the No. 2 engine moving control rod to the continuously variable transaxle assembly with the 4 bolts.
Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (D) → Fully tighten bolt (A)
51201
12.INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Slowly jack up the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.
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.
Use attachments to keep the front suspension crossmember sub-assembly level.
Install the front suspension crossmember sub-assembly to the vehicle body with the 4 bolts.
Lower the engine lifter.
Install the No. 2 engine moving control rod with the bolt.
51108A
13.INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH
51107A
14.INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH
32101G
15.INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT
Clean the threads of the 6 drive plate and torque converter assembly setting bolts.
| *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.
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
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.
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.
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.
11361J
16.INSTALL FLYWHEEL HOUSING UNDER COVER
45025D
17.CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
45260
18.CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
45259A
19.INSTALL COLUMN HOLE COVER SILENCER SHEET
20.REMOVE ENGINE SUPPORT BRIDGE
Remove SST from the vehicle body.
Prevent SST from contacting the vehicle body or windshield glass.
Connect the inlet hose to the vehicle body with the clip.
21.REMOVE ENGINE HANGERS
82286A
22.CONNECT NO. 2 EARTH WIRE
Install the bolt to connect the No. 2 earth wire to the engine mounting insulator sub-assembly RH.
23.INSTALL WIRE HARNESS CLAMP BRACKET
28100
24.INSTALL STARTER ASSEMBLY
25.CONNECT WATER BY-PASS HOSE
Engage the 2 clamps to install the water by-pass hose to the continuously variable transaxle assembly.
Connect the No. 3 water by-pass hose and No. 4 water by-pass hose to the transmission oil cooler and slide the 2 clips to secure them.
Fully insert the No. 3 water by-pass hose and No. 4 water by-pass hose to the 2nd rib on each oil cooler pipe.
82121
26.CONNECT ENGINE WIRE
Engage the 3 clamps to connect the engine wire to the front suspension crossmember sub-assembly.
Engage the 8 clamps.
Connect the oil pump with motor assembly connector.
Connect the oil pressure sensor connector.
Connect the transmission revolution sensor (NOUT) connector.
Connect the park/neutral position switch assembly connector.
Connect the transmission revolution sensor (NIN) connector.
Connect the transmission wire connector.
Connect the engine wire to the continuously variable transaxle assembly with the bolt.
17410
27.INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)
57533B
28.INSTALL FRONT FLOOR CENTER BRACE
58166A
29.INSTALL FRONT FLOOR COVER LH
58165C
30.INSTALL FRONT FLOOR COVER RH
35141F
31.CONNECT NO. 1 BREATHER PLUG (CVT)
Connect the No. 1 breather plug (CVT) to the clamp.
33823
32.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.
33820B
33.CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
74404A
34.INSTALL BATTERY CLAMP SUB-ASSEMBLY
35.CONNECT ENGINE WIRE
36.INSTALL BATTERY
89661
37.INSTALL ECM
17701
38.INSTALL AIR CLEANER CASE SUB-ASSEMBLY
17705
39.INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
17751
40.INSTALL INLET NO. 1 AIR CLEANER
53289A
41.INSTALL RADIATOR SUPPORT OPENING COVER (for TFTM Made)
53289A
42.INSTALL RADIATOR SUPPORT OPENING COVER (for GTMC Made)
55701J
43.INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
Remove the 4 nuts.
Install the outer cowl top panel sub-assembly with the 9 bolts and 4 nuts.
55737B
44.INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (w/ No. 1 Heater Air Duct Splash Shield Seal)
45.INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
46.ADD ENGINE COOLANT
47.INSTALL FRONT DRIVE SHAFT ASSEMBLY (for TFTM Made)
48.INSTALL FRONT DRIVE SHAFT ASSEMBLY (for GTMC Made)
49.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
50.INSPECT SHIFT LEVER POSITION
51.ADJUST SHIFT LEVER POSITION (for TFTM Made)
52.ADJUST SHIFT LEVER POSITION (for GTMC Made)
53.INSPECT FOR COOLANT LEAK
54.INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL
55.INSPECT FOR EXHAUST GAS LEAK
56.RESET MEMORY
57. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL
When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.