Installation

K41B CVT: CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY: INSTALLATION

1. INSTALL TRANSMISSION CASE PLUG ASSEMBLY

HINT
After replacing the CVT, perform the following procedure.

(a) Apply Toyota Genuine CVT Fluid TC to the O-ring on a new transmission case plug.

(b) Install the transmission case plug onto the CVT.

2. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket with the bolt to the CVT.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(b) Install the 3 wire harness clamp brackets with the 3 bolts to the CVT.

*1 - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

*2 - Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(c) Install the 2 wire harness clamp brackets with the 2 bolts to the CVT.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

3. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the No. 1 transmission control cable bracket onto the CVT with the 2 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

4. INSTALL ENGINE MOUNTING BRACKET LH

(a) Clean and degrease the bolts and the installation holes in the engine mounting bracket LH.

(b) Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the engine mounting bracket LH onto the CVT with the 3 bolts.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

HINT
Tighten the bolts in the following order:

*1 (Temporarily tighten) ->

*2 (Fully tighten) ->

*3 (Fully tighten) ->

*1 (Fully tighten)

5. INSTALL ENGINE MOUNTING STAY LH

(a) Install the engine mounting stay LH onto the CVT and engine mounting bracket LH with the 2 bolts.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

HINT
Tighten the bolts in the following order:

*1 (Temporarily tighten) ->

*2 (Fully tighten) ->

*1 (Fully tighten)

6. INSTALL CVT OIL PUMP TYPE T OIL SEAL

(a) Ensure that there is no dirt or foreign matter on your hands, and then apply genuine TOYOTA MP grease No. 2 to the entire periphery of the lip of a new CVT oil pump type T oil seal.

(b) Temporarily attach the CVT oil pump type T oil seal by pressing it onto the installation surface of the oil pump housing manually.

(c) Clean the oil seal contact section of the SST and the area around it.

(d) Using the SST, drive the CVT oil pump type T oil seal in evenly, as far as the side surface of the oil pump housing.

SST : 09309-36010

NOTICE:
* Drive the oil seal in gradually, while visually checking the parallelism.
* After the installation, confirm that the oil seal has been driven in as far as the side surface of the oil pump housing.
* Wipe off any grease that has oozed out with your hand.

HINT
The oil seal should be driven in between 0 and 0.5 mm (as measured from the side surface of the oil pump housing).

7. INSTALL TORQUE CONVERTER ASSEMBLY

(a) Clean and degrease the 6 holes for the torque converter set bolts.

(b) Make a matchmark to indicate the position of the torque converter protrusion (*1).

Text in Illustration

Text in Illustration

NOTICE:
Make the housing matchmark at the wide groove. The matchmark position must be correct to prevent damage.

(d) Align the matchmarks on the housing and torque converter and engage the input shaft splines with the turbine runner.

Text in Illustration

NOTICE:
* Maintain the torque converter in a horizontal position when installing the input shaft.
* Be sure to not damage the oil seal.

(e) Rotate the torque converter to engage the stator shaft splines with the stator splines.

Text in Illustration

NOTICE:
Maintain the torque converter in a horizontal position when installing the stator shaft.

HINT
Rotate the torque converter about 180 degrees.

(f) Rotate the torque converter clockwise until the matchmark aligns with the matchmark on the case, and then engage the grooves in the oil pump drive gear with the claws in the torque converter.

Text in Illustration

NOTICE:
* Maintain the torque converter in a horizontal position when installing the input shaft and stator shaft.
* Do not push the torque converter while aligning the matchmarks.

(g) Using a vernier caliper, measure the distance from the CVT fitting surface on the engine to the torque converter fitting surface on the drive plate (dimension A).

Text in Illustration

(h) Using a vernier caliper and a straightedge, measure the distance from the set block to the housing end (dimension B) and check that dimension B is greater than dimension A.

Standard distance:

B=A+1 mm (0.0394 in.) or more

NOTICE:
Ensure that the torque converter is inserted all the way into the CVT. If the converter is not inserted sufficiently when the CVT is installed onto the engine, the CVT and torque converter could be damaged.

8. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE

(a) Confirm that 2 knock pins are on the transaxle contact surface of the engine cylinder block before transaxle installation.

Text in Illustration

(b) Apply clutch spline grease to the round of the crankshaft contact surface with the torque converter centerpiece.

Clutch spline grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum spread:

Approximately 1 g (0.353 oz)

(c) Maintain the engine and CVT in a horizontal position, align the knock pins and holes (*4), and tighten the 9 bolts shown the illustration.

*1 - Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

*2 - Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

*3 - Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)

NOTICE:
* Confirm that there are 2 knock pins on the fitting surface of the engine block before installing the CVT.
* Do not twist or apply excessive force to the CVT.
* Check that the torque converter rotates smoothly after installation of the CVT.

HINT

Bolt length

* *1: 45 mm (1.77 in.)
* *2: 45 mm (1.77 in.)
* *3: 35 mm (1.38 in.)

9. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

(a) Clean and degrease the 6 drive plate and torque converter setting bolts.

(b) Apply adhesive to 2 or 3 threads on the ends of the 6 torque converter set bolts.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Use SST to hold the crankshaft pulley in place.

SST : 09960-10010

09962-01000

09963-01000

(d) Install the 6 torque converter set bolts.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

HINT
Tighten the black-colored bolt first, and then tighten the 5 silver-colored bolts.

10. INSTALL STARTER ASSEMBLY Installation

11. INSTALL ENGINE MOUNTING CONTROL BRACKET

(a) Install the engine mounting control bracket onto the CVT with the 4 bolts.

Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)

HINT
Tighten the bolts in the following order:

*1 (Temporarily tighten) ->

*3 (Fully tighten) ->

*2 (Fully tighten) ->

*1 (Fully tighten)

12. INSTALL ENGINE WIRE

(a) Engage the 3 clamps and install the engine wire to the CVT.

(b) Connect the park/neutral position switch connector, the transmission wire connector, and the 2 transmission revolution sensor connectors (NIN, NT).

Text in Illustration

(c) Install the engine wire onto the CVT with the bolt.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(d) Engage the 5 clamps and install the engine wire to the CVT.

Text in Illustration

(e) Connect the heated oxygen sensor connector, oil pressure sensor connector and the transmission revolution sensor (NOUT) connector.

13. INSTALL WATER BY-PASS HOSE ASSEMBLY

(a) Connect the 2 water by-pass hoses to the oil cooler with the 2 clamps.

Text in Illustration

NOTICE:
Securely push the hoses over each pipe fitting on the transmission oil cooler until the hoses contact the rib on each pipe fitting.

(b) Install the water by-pass hose onto the CVT with the bolt.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(c) Engage the clamp and install the breather hose to the breather hose clamp.

Text in Illustration

HINT
* Install the breather hose clamp so that the top end of it overlaps the painted area.
* Install the breather hose clamp so that its protuberance is within the painted area.

14. INSTALL DRIVE SHAFT HEAT INSULATOR BRACKET

(a) Install the drive shaft heat insulator bracket onto the engine with the 2 bolts.

Torque : 16 Nm (166 kgf-cm, 12 ft-lbf)

15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

Installation

16. RESET MEMORY (CVT initialization)

NOTICE:
Perform Reset Memory (CVT initialization) when replacing the CVT Programming and Relearning.