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Home >> Lexus >> 2020 >> UX 200 Luxury >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Continuously Variable Transaxle (CVT) System (K120) (Service Information) (1 Of 2) >> CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (When Not Using the Engine Support Bridge) >> Installation [08/2021 - 07/2022] >> Procedure

Installation [08/2021 - 07/2022]: Procedure

  1. INSTALL BREATHER PLUG SUB-ASSEMBLY 

    HINT: 

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

    1. Apply Toyota Genuine CVT fluid FE to a new O-ring, and install it to the breather plug.
      NOTE:

      Be careful not to damage or twist the O-ring.

    2. Install the breather plug cap to the breather plug.
    3. Install the breather plug sub-assembly to the continuously variable transaxle assembly.
  2. INSTALL TRANSMISSION CASE PLUG ASSEMBLY 
    1. Apply Toyota Genuine CVT fluid FE to a new O-ring, and install it to the transmission case plug assembly.
    2. Install the transmission case plug assembly to the continuously variable transaxle assembly.
  3. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. 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 
    1. 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) 

      GTY808077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 
    1. 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) 

      GTY801173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 ENGINE MOVING CONTROL ROD 
    1. 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) 

      Fig 1: Engine Moving Control Rod Tightening Sequence
      GTY807872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten
  7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the front suspension crossmember sub-assembly to the No. 2 engine moving control rod with the bolt.

      Torque: 170 N.m (1734 kgf/cm, 125 ft.lbf) 

  8. INSTALL CVT TYPE T OIL SEAL 
    1. 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 type T oil seal.
    2. Temporarily install the CVT type T oil seal by pressing it to the installation surface of the oil pump housing by hand.
      NOTE:

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

    3. Clean the CVT type T oil seal contact surface of SST and the area around it.
      • SST: 09223-00010 
    4. Using SST and a hammer, drive the CVT type T oil seal in evenly, until it is even with the side surface of the transaxle housing.
      GTY800808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Standard Depth

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

      NOTE:
      • Drive the CVT type T oil seal in gradually, while visually checking that it is even.
      • After installation, confirm that the CVT 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.
  9. INSTALL TORQUE CONVERTER ASSEMBLY 
    1. Set the key at the top of the drive sprocket and put a matchmark on the transaxle housing.
      GTY838570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
      *b Key
    2. Place a matchmark on the torque converter assembly so that the position of its groove is clearly indicated.
      GTY824643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Groove
      *b Matchmark
    3. 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.
      GTY811957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the torque converter assembly to the input shaft while keeping it horizontal.
      • Do not damage the CVT Type T Oil Seal.
    4. Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly.
      GTY834098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 CVT Type T Oil Seal
      *a Matchmark
      NOTE:
      • Install the torque converter assembly to the input shaft while keeping it horizontal.
      • Do not damage the CVT Type T Oil Seal.
    5. 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 groove of the torque converter assembly into the key of the drive sprocket.
      GTY800229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 CVT Type T Oil Seal
      *a Matchmark
      NOTE:
      • 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 type T oil seal.
    6. Clean the drive plate and torque converter assembly setting bolt holes.
    7. 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.
      GTY777418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Assembly Surface
      *b Drive Plate Surface
      NOTE:

      Make sure to deduct the thickness of the straightedge.

    8. 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.
      GTY804701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard

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

      NOTE:
      • 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.
  10. INSTALL ENGINE ASSEMBLY 
    1. Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.
      GTY825579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.)

    2. Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.
      GTY819175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin
    3. Install the continuously variable transaxle assembly to the engine assembly with the 8 bolts.

      Bolt (A) 

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

      Bolt (B) 

      Torque: 25 N.m (255 kgf/cm, 18 ft.lbf) 

      Bolt (C) 

      Torque: 46 N.m (469 kgf/cm, 34 ft.lbf) 

      NOTE:
      • 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 continuously variable transaxle assembly side
      • Bolt (C): Install from engine assembly side
  11. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Install the engine mounting bracket LH to the continuously variable transaxle assembly with the 6 bolts in the order shown in the illustration.
      Fig 2: Engine Mounting Bracket LH Bolts Tightening Sequence
      GTY1087070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten

      Torque: 41 N.m (418 kgf/cm, 30 ft.lbf) 

  12. INSTALL FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 11

  13. INSTALL STARTER ASSEMBLY 

    Refer to INSTALLATION [10/2018 - 07/2022]

  14. CONNECT WATER HOSE 
    1. 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) 

    2. Connect the water by-pass hose assembly to the No. 3 water by-pass pipe sub-assembly and slide the hose clip to secure it.
    3. Install the flow shutting valve (water valve) to the water hose clamp bracket with the bolt.

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

    4. Engage the clamp.
    5. Connect the 2 water hoses to the transmission oil cooler and slide the 2 hose clips to secure them.
  15. INSTALL TCM 
    NOTE:

    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.

    1. Install the TCM to the continuously variable transaxle assembly with the 2 bolts.

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

  16. CONNECT ENGINE WIRE 
    1. Engage the 3 clamps to connect the engine wire to the front suspension crossmember sub-assembly.
    2. Engage the 4 clamps to connect the engine wire to the continuously variable transaxle assembly.
      GTY968644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transmission Wire Connector *2 Shift Stroke Sensor Connector
      *3 Park/Neutral Position Switch Connector *4 Transmission Revolution Sensor (NOUT) Connector
      *5 TCM Connector *6 Transmission Revolution Sensor (NSS) Connector
      *7 Oil Pressure Sensor Connector *8 Transmission Revolution Sensor (NT) Connector
      Install in this Direction - -
    3. Connect the engine wire to the continuously variable transaxle assembly with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 89 in.lbf) 

    4. Connect the transmission revolution sensor (NT) connector.
    5. Connect the oil pressure sensor connector.
    6. Connect the transmission revolution sensor (NSS) connector.
    7. 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.

    8. Connect the transmission revolution sensor (NOUT) connector.
    9. Connect the park/neutral position switch connector.
    10. Connect the shift stroke sensor connector.
    11. 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.

    12. Engage the 3 clamps to connect the engine wire to the continuously variable transaxle assembly.
      GTY804632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Flow Shutting Valve (Water Valve) Connector
    13. Connect the engine wire to the continuously variable transaxle assembly with the bolt.

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

    14. Connect the flow shutting valve (water valve) connector.
    15. Connect the engine coolant temperature sensor connector.
      GTY811881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Position Sensor Connector
      *2 Engine Coolant Temperature Sensor Connector
    16. Connect the camshaft position sensor connector.
    17. Connect the engine wire to the engine assembly with the bolt and 2 nuts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  17. REMOVE ENGINE HANGER 

    Refer to PROCEDURE - Step 15

  18. INSTALL FUEL DELIVERY GUARD 

    Refer to PROCEDURE - Step 16

  19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

    Refer to INSTALLATION [08/2021 - 07/2022]

  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 
    1. Clean the threads of the 6 drive plate and torque converter assembly setting bolts.
    2. 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.
      GTY495166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      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.

    3. 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) 

      NOTE:

      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.

  21. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover to the cylinder block sub-assembly.
      GTY779968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  22. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY 
    1. Temporarily install the drive shaft heat insulator sub-assembly to the cylinder block sub-assembly with the 3 bolts.
    2. Tighten the 3 bolts in the order shown in the illustration.

      Torque: 17.6 N.m (179 kgf/cm, 13 ft.lbf) 

      Fig 3: Drive Shaft Heat Insulator Sub-Assembly Bolt Tightening Sequence
      GTY814613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten
  23. RESET MEMORY 

    Refer to INITIALIZATION [10/2018 - 07/2022]

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