K313 CVT  CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY  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

Hide 35012B 1.INSTALL BREATHER PLUG HOSE

HINT:

Perform this procedure only when replacement of the breather plug hose is necessary.


a.

Install the No. 1 breather plug (CVT) to the breather plug hose.


b.

Install the breather plug hose with the No. 1 breather plug (CVT) to the continuously variable transaxle assembly.


Hide 2.INSTALL WITH HEAD STRAIGHT SCREW PLUG

HINT:

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


a.

Install the with head straight screw plug to the continuously variable transaxle assembly with a new gasket.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


Hide 3.INSTALL WIRE HARNESS CLAMP BRACKET

a.

Install the 4 wire harness clamp brackets and water by-pass hose clamp bracket to the continuously variable transaxle assembly with the 5 bolts.

Torque:
12.8 N*m (131 kgf*cm, 9 ft.*lbf)


b.

Install the water by-pass hose clamp to the water by-pass hose clamp bracket.


Hide 12325A 4.INSTALL ENGINE MOUNTING BRACKET LH

a.

Clean the bolts and the installation holes in the engine mounting bracket LH.


b.
P000601C21
1.99,1.458 1.667,1.833 false 1.583,1.854 1.833,2.094 0.25,0.24 10 false *a
*a Adhesive


Apply adhesive to 2 or 3 threads on the ends of the 4 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent


NOTICE:

In order to ensure proper installation of the 4 bolts, apply adhesive to the 4 bolts and install them within 10 minutes of adhesive application.



c.

Install the engine mounting bracket LH to the continuously variable transaxle assembly with the 4 bolts.

Torque:
52 N*m (530 kgf*cm, 38 ft.*lbf)


Hide 12321A 5.INSTALL REAR ENGINE MOUNTING BRACKET

a.

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

Torque:
64 N*m (653 kgf*cm, 47 ft.*lbf)


Hide 12311A 6.INSTALL FRONT ENGINE MOUNTING BRACKET

a.

Install the front engine mounting bracket to the continuously variable transaxle assembly with the 4 bolts.

Torque:
45 N*m (459 kgf*cm, 33 ft.*lbf)


Hide 33823 7.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)


Hide 30400E 8.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 manually.


c.
C208789C01
1.802,1.792 1.802,2.469 false 1.698,2.5 2.125,2.74 0.427,0.24 10 SST 0.917,2.458 1.135,2.656 0.219,0.198 10 *a
*a 0 to 0.5 mm (0 to 0.0197 in.)


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


d.

Using SST, drive the CVT oil pump type T oil seal in evenly, until it is even with the side surface of the oil pump housing.

SST
09309-36010  

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.



HINT:

The CVT oil pump type T oil seal should be driven in between 0 to 0.5 mm (0 to 0.0197 in.) as measured from the side surface of the oil pump housing.



Hide 32000A 9.INSTALL TORQUE CONVERTER ASSEMBLY

a.
C235921C02
2.396,0.521 2.292,0.521 2.292,0.521 2.167,1.25 false 0.583,1.604 0.667,1.604 0.667,1.604 0.781,1.406 false 1.021,2.021 1.125,2.021 1.125,2.021 1.063,1.677 false 0.865,0.656 0.938,0.656 0.938,0.656 1.021,1.115 false 1.521,0.906 1.438,0.906 1.438,0.906 1.344,1.385 false 2.427,0.438 2.625,0.615 0.198,0.177 10 *a 0.708,0.563 0.906,0.74 0.198,0.177 10 *b 0.854,1.927 1.052,2.104 0.198,0.177 10 *b 0.417,1.51 0.615,1.688 0.198,0.177 10 *c 1.542,0.823 1.74,1 0.198,0.177 10 *c
*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 housing to indicate the position of the groove.

NOTICE:
·

Place the matchmark on the housing to indicate the position of the wide groove.

·

The matchmark position must be correct to prevent damage.




b.
C289748C01
1.781,0.323 2.292,0.323 false 1.417,1.979 1.719,1.979 1.719,1.979 1.719,1.729 true 2.344,0.219 2.563,0.427 0.219,0.208 10 false *a 1.229,1.896 1.448,2.104 0.219,0.208 10 false *b
*a Key
*b Matchmark


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


c.
C303725C01
2.417,1.625 1.792,2.906 1.792,2.906 2.438,2 true 1.24,1.094 1.75,0.688 1.75,0.688 1.229,1.26 true 1.615,2.854 1.927,3.052 0.313,0.198 10 false *1 1.823,0.573 2.135,0.771 0.313,0.198 10 false *a
*1 CVT Oil Pump Type T Oil Seal
*a Matchmark


Align the matchmark on the 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.




d.
C303726C01
2.531,1.646 1.833,2.896 1.833,2.896 2.521,2 true 0.75,2.802 0.896,2.802 0.896,2.802 1.198,2.156 true 1.698,0.396 1.552,0.396 1.552,0.396 1.25,1.052 true 1.656,2.833 1.969,3.031 0.313,0.198 10 false *1 1.76,0.292 2.073,0.49 0.313,0.198 10 false *a 0.573,2.719 0.885,2.917 0.313,0.198 10 false *a
*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.

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.




e.
C303727C01
2.521,1.625 1.792,2.948 1.792,2.948 2.531,2.01 true 1.25,1.063 1.729,0.542 1.729,0.542 1.25,1.177 true 1.615,2.885 1.927,3.083 0.313,0.198 10 false *1 1.781,0.417 2.094,0.615 0.313,0.198 10 false *a
*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 housing and insert the key of the torque converter assembly into the groove of the oil pump drive gear.

NOTICE:
·

Do not push the torque converter assembly excessively when rotating it.

·

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

·

Do not damage the CVT oil pump type T oil seal.




f.

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


g.
C273897C02
1.208,3.135 1.104,3.135 1.104,3.135 0.885,2.448 false 1.313,0.906 1.573,0.521 1.573,0.521 1.677,0.521 false 2.417,1.063 2.51,1.063 2.51,1.063 2.615,0.688 false 2.479,1.958 2.583,1.958 2.583,1.958 2.708,1.594 false 2.26,0.969 2.458,1.146 0.198,0.177 10 *a 2.313,1.865 2.479,2.031 0.167,0.167 10 *b 1.729,0.438 1.927,0.625 0.198,0.188 10 *a 1.24,3.052 1.438,3.24 0.198,0.188 10 *b 2.26,0.229 2.469,0.417 0.208,0.188 10 A
*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 assembly*a and the torque converter assembly contact surfaces of the drive plate*b.


h.
C303728N01
2.344,0.354 2.5,0.552 0.156,0.198 10 false B

Using a vernier caliper and straightedge, measure the dimension (B) shown in the illustration and check that dimension (B) is more than dimension (A), which was measured in the previous step.

Standard:

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.




Hide 30400 10.INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

a.
C303729C01
1.667,1.26 2.25,1.844 2.25,1.844 2.448,1.844 true 0.823,0.99 1.135,1.146 0.313,0.156 10 false *1 2.521,1.76 2.833,1.917 0.313,0.156 10 false *2
*1 Crankshaft
*2 Torque Converter Assembly Centerpiece


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)



b.
C274303C02
0.5,0.625 1.115,0.625 false 2.385,0.917 2.927,0.917 false 0.333,0.563 0.646,0.76 0.313,0.198 10 false *1 2.969,0.844 3.198,1.042 0.229,0.198 10 false *1 2.323,2.292 2.479,2.51 0.156,0.219 10 false A 1.125,2.365 1.281,2.563 0.156,0.198 10 false A 0.833,3.208 0.99,3.406 0.156,0.198 10 false B 1.094,4.01 1.25,4.208 0.156,0.198 10 false B 1.51,4.323 1.667,4.521 0.156,0.198 10 false B 2.052,4.396 2.208,4.594 0.156,0.198 10 false B 2.521,4.229 2.677,4.427 0.156,0.198 10 false B
*1 Knock Pin


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


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)

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 2 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): Install from continuously variable transaxle assembly side

·

Bolt (B): Install from engine assembly side




Hide 28100 11.INSTALL STARTER ASSEMBLY

Click hereEngine / Hybrid System>2ZR-FE STARTING>STARTER>INSTALLATION

Hide 11363A 12.INSTALL FLYWHEEL HOUSING SIDE COVER

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

Hide 82121 13.CONNECT ENGINE WIRE

a.

Engage the 6 clamps.


b.

Connect the transmission wire connector.


c.

Connect the transmission revolution sensor (NIN) connector.


d.

Connect the park/neutral position switch assembly connector.


e.

Connect the oil pressure sensor connector.


f.

Connect the transmission revolution sensor (NOUT) connector.


Hide 16282 14.CONNECT NO. 5 WATER BY-PASS HOSE

a.

Connect the No. 5 water by-pass hose and slide the 3 clips to secure it.

NOTICE:

Fully insert the No. 5 water by-pass hose to the 2nd rib on each oil cooler pipe.



b.

Engage the clamp.


Hide 12371A 17.TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

Hide 12361A 18.TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

Hide 19.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

Hide 51204A 20.TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>INSTALLATION

Hide 51201 21.INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>INSTALLATION

Hide 51204A 22.FULLY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>INSTALLATION

Hide 32101G 23.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.
A057108C45
1.708,1.906 1.948,1.5 false 1.552,1.833 1.75,2.021 0.198,0.188 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 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.



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 bolt while holding the crankshaft pulley with SST.

SST
09213-54015  
09330-00021  

HINT:

Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)


Torque:
28 N*m (286 kgf*cm, 21 ft.*lbf)

NOTICE:

First install the black-colored bolt, and then the remaining 5 silver-colored bolts.



Hide 11361J 24.INSTALL FLYWHEEL HOUSING UNDER COVER

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION