K121 CVT  CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY  INSTALLATION  

0.198,0.115 0.469,0.354 0.271,0.24 12 false *A 1.521,0.115 1.833,0.354 0.313,0.24 12 false *B

*A	for Type A
*B	for Type B

for Type A:

Install the 5 wire harness clamp brackets to the continuously variable transaxle assembly with the 6 bolts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

2.688,1 2.927,1.229 0.24,0.229 10 true *a 0.833,1.563 1.042,1.76 0.208,0.198 10 true *b 2.542,0.125 2.76,0.313 0.219,0.188 10 true *c 1.76,2 1.958,2.177 0.198,0.177 10 true *d 0.927,0.323 1.24,0.479 0.313,0.156 10 true *e

*a	Bolt A
*b	Bolt B
*c	Bolt C
*d	Bolt D
*e	Bolt E

Install the engine mounting bracket sub-assembly LH to the continuously variable transaxle assembly with the 5 bolts.

Torque:

42 N*m (428 kgf*cm, 31 ft.*lbf)

HINT:

Tightening order: Temporarily install bolt (A) → Tighten bolt (B) → Tighten bolt (D) → Tighten bolt (A) → Tighten bolt (C) → Tighten bolt (E)

1.667,2.583 1.667,2.167 false 0.844,2.667 1.156,2.823 0.313,0.156 10 false *a 1.583,2.594 1.896,2.75 0.313,0.156 10 false SST

*a

Depth

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 oil pump 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 oil pump housing.

·

Wipe any extra grease off with your hand.

1.323,0.458 1.823,0.167 true 2.469,0.521 2.771,0.979 true 1.833,0.052 2.146,0.208 0.313,0.156 10 false *a 2.24,0.427 2.427,0.604 0.188,0.177 10 true *b

*a	Matchmark
*b	Key

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

1.396,0.292 1.552,0.292 1.552,0.292 1.75,0.615 false 1.396,1.896 1.552,1.896 1.552,1.896 1.719,1.542 false 1.24,0.198 1.531,0.427 0.292,0.229 10 false *a 1.219,1.802 1.49,2.063 0.271,0.26 10 false *b

*a	Groove
*b	Matchmark

Place a matchmark on the torque converter assembly so that the position of its groove is clearly indicated.

2.49,1.396 1.719,1.958 1.719,1.958 2.5,1.063 true 1.313,0.667 0.458,0.208 0.458,0.208 1.302,0.49 true 1.552,1.896 1.865,2.052 0.313,0.156 10 false *1 0.313,0.094 0.625,0.25 0.313,0.156 10 false *a

*1	Transaxle Housing 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.

NOTICE:

·

Install the torque converter assembly to the input shaft while keeping it horizontal.

·

Do not damage the transaxle housing type T oil seal.

1.333,0.521 1.729,0.198 true 2.479,1.375 1.677,1.99 1.677,1.99 2.49,1.073 true 0.906,2.01 1.302,1.688 true 1.5,1.938 1.813,2.094 0.313,0.156 10 false *1 1.76,0.115 2.073,0.271 0.313,0.156 10 false *a 0.76,1.938 1.073,2.094 0.313,0.156 10 false *a

*1	Transaxle Housing 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.

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.

2.469,1.354 1.76,1.938 1.76,1.938 2.448,1.031 true 1.333,0.677 1.865,0.188 1.865,0.188 1.344,0.531 true 1.625,1.906 1.938,2.063 0.313,0.156 10 false *1 1.885,0.052 2.198,0.208 0.313,0.156 10 false *a

*1	Transaxle Housing 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 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.

0.635,2.74 1.052,2.323 true 2.427,1.823 2.833,1.427 false 2.344,1.031 2.51,0.771 false 0.563,0.208 1.146,0.792 true 2.146,0.938 2.458,1.094 0.313,0.156 10 false *a 2.25,1.74 2.563,1.896 0.313,0.156 10 false *b 2.177,0.198 2.375,0.385 0.198,0.188 10 false A 0.365,0.094 0.677,0.25 0.313,0.156 10 false *a 0.438,2.656 0.75,2.813 0.313,0.156 10 false *b

*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.

NOTICE:

Make sure to deduct the thickness of the straightedge.

2.667,0.51 2.823,0.708 0.156,0.198 10 false 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.

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.

1.604,0.875 2.573,0.417 true 0.948,0.99 1.26,1.146 0.313,0.156 10 false *1 2.646,0.323 2.958,0.479 0.313,0.156 10 false *2

*1	Crankshaft
*2	Torque Converter Assembly Centerpiece
	Clutch Spline Grease

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)

2.24,2.365 2.396,2.563 0.156,0.198 10 false -

	Bolt A
	Bolt B
	Bolt C
	Knock Pin

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

0,0 0,0 false

	Bolt A
	Bolt B
	Bolt C

Install the rear engine mounting bracket sub-assembly to the continuously variable transaxle with the 4 bolts.

Torque:

42 N*m (428 kgf*cm, 31 ft.*lbf)

HINT:

Tightening order: Temporarily install bolt (A) → Tighten bolt (B) → Tighten bolt (A) → Tighten bolt (C)

1.333,0.438 1.49,0.635 0.156,0.198 10 false -

	Bolt A
	Bolt B
	Bolt C

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

Torque:

42 N*m (428 kgf*cm, 31 ft.*lbf)

HINT:

Tightening order: Temporarily install bolt (A) → Tighten bolt (B) → Tighten bolt (C) → Tighten bolt (A)

Connect the No. 3 water by-pass hose and No. 4 water by-pass hose to the water by-pass pipe sub-assembly, and slide the 2 hose clips to secure the hoses.

3.198,0.219 3.615,0.219 true 4.083,0.208 4.5,0.208 true 6.281,1.458 6.5,0.917 6.5,0.917 6.667,0.917 false 6.708,1.469 6.51,0.927 true 1.885,1.229 2.198,1.385 0.313,0.156 10 false *a 6.375,2 6.688,2.156 0.313,0.156 10 false *a 2.958,0.135 3.156,0.313 0.198,0.177 10 true *1 4.552,0.125 4.865,0.281 0.313,0.156 10 true *2 5.802,0.854 6.042,1.063 0.24,0.208 10 false *e 0.917,2.177 1.229,2.333 0.313,0.156 10 false *b 6.698,0.844 7.01,1 0.313,0.156 10 false *c 1.135,1.031 1.448,1.229 0.313,0.198 10 false *d 5.688,1.354 5.885,1.573 0.198,0.219 10 true *f 5.156,0.802 5.469,1 0.313,0.198 10 false *g

*1	No. 3 Water By-pass Hose	*2	No. 4 Water By-pass Hose
*a	2 to 7 mm (0.0787 to 0.275 in.)	*b	0 to 3 mm (0 to 0.118 in.)
*c	Paint Mark (Rear Side of Vehicle)	*d	90° (Claw of Hose Clip Location)
*e	120° (Claw of Hose Clip Location)	*f	RR Side
*g	Upper Side	-	-

NOTICE:

·

Make sure to slide the No. 3 water by-pass hose and No. 4 water by-pass hose until it contacts the hose stopper of the transmission oil cooler.

·

Align the hose paint mark the position shown in the illustration.

·

Make sure that the claws of the hose clip are within the location shown in the illustration.

2.25,2.667 2,2.333 2,2.333 2.427,2.667 true 2.521,3.156 2.833,3.313 0.313,0.156 10 false *a 1.865,2.198 2.177,2.354 0.313,0.156 10 false *b 1.406,2.313 1.719,2.469 0.313,0.156 10 false *c

*a	2 to 7 mm (0.0787 to 0.275 in.)
*b	Paint Mark (LH Side of Vehicle)
*c	120° (Claw of Hose Clip Location)

Connect the No. 2 water by-pass hose to the transmission oil cooler and slide the hose clip to secure the hose.

NOTICE:

·

Make sure to slide the No. 2 water by-pass hose until it contacts the hose stopper of the transmission oil cooler.

·

Align the hose paint mark the position shown in the illustration.

·

Make sure that the claws of the hose clip are within the location shown in the illustration.

Connect the No. 1 water by-pass hose to the transmission oil cooler and slide the hose clip to secure the hose.

5.021,1.385 5.323,1.771 5.323,1.771 4.844,1.406 true 5.677,1.146 5.917,1.396 0.24,0.25 10 false *c 4.74,0.646 5.052,0.802 0.313,0.156 10 false *b 5.344,1.677 5.656,1.875 0.313,0.198 10 false *a

*a	Paint Mark (Upper Side of Vehicle)	*b	2 to 7 mm (0.0787 to 0.275 in.)
*c	120° (Claw of Hose Clip Location)	-	-

NOTICE:

·

Make sure to slide the No. 1 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. 1 water by-pass hose with the paint mark of the transmission oil cooler.

·

Make sure that the claws of the hose clip are within the location shown in the illustration.

Attach the 2 clamps to connect the engine wire.

Attach the 5 clamps to connect the engine wire to the continuously variable transaxle assembly.

3.333,0.125 3.583,0.281 0.25,0.156 10 true *a 4.26,0.188 4.5,0.354 0.24,0.167 10 true *b 3.938,1.365 4.125,1.583 0.188,0.219 10 true *c 4.313,0.625 4.5,0.802 0.188,0.177 10 true *d 4.594,2.042 4.906,2.198 0.313,0.156 10 true *e 4.125,2.427 4.292,2.594 0.167,0.167 10 true *f 3.135,1.708 3.458,1.927 0.323,0.219 10 false *g 3.344,2.302 3.563,2.469 0.219,0.167 10 true *h

*a	Transmission Wire Connector	*b	Shift Stroke Sensor Connector
*c	Shift Lever Position Sensor Connector	*d	Transmission Revolution Sensor (NOUT) Connector
*e	Transmission Revolution Sensor (NSS) Connector	*f	Oil Pressure Sensor Connector
*g	Transmission Revolution Sensor (NT) Connector	*h	Oil Pump With Motor Assembly Connector
	Install in this Direction	-	-

2.25,1.396 2.51,2.01 2.51,2.01 2.875,2.01 true 2.906,1.938 3.104,2.135 0.198,0.198 10 true *1

*1	Flow Shutting Valve (Water Valve) Connector

Attach the clamp to connect the engine wire.

1.354,0.365 2.333,0.167 2.333,0.167 2.5,0.167 true 2.167,1.333 2.833,0.667 2.833,0.667 3,0.667 true 2.542,0.104 2.771,0.313 0.229,0.208 10 true *1 3.031,0.594 3.25,0.76 0.219,0.167 10 true *2

*1	Camshaft Position Sensor Connector
*2	Engine Coolant Temperature Sensor Connector

Connect the engine coolant temperature sensor connector.

1.729,1.865 2.021,1.865 2.021,1.865 2.094,1.49 false 1.531,1.75 1.844,1.906 0.313,0.156 10 false *a

*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 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 setting bolts, apply adhesive to the 6 drive plate and torque converter setting bolts and install them within 10 minutes of adhesive application.