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Removal [09/2022 - 11/2022]: Procedure

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  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [09/2022 - ]

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  4. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  5. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [01/2019 - 11/2022]

  6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [09/2022 - 11/2022]

  7. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 3

  8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 
    1. Remove the 9 bolts, 4 nuts and outer cowl top panel sub-assembly.
      GTY916836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 nuts.
      GTY931790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

  9. REMOVE RADIATOR SUPPORT OPENING COVER 

    Refer to PROCEDURE - Step 1

  10. REMOVE INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 4

  11. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 2

  12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  14. REMOVE ECM 

    Refer to PROCEDURE - Step 8

  15. REMOVE BATTERY 

    Refer to REMOVAL [09/2022 - 11/2022]

  16. DISCONNECT ENGINE WIRE 

    See step  11

  17. REMOVE BATTERY CLAMP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

  18. DISCONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE 

    See step  13

  19. DISCONNECT NO. 1 BREATHER PLUG (CVT) 
    1. Disconnect the No. 1 breather plug (CVT) from the clamp.
      GTY916816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to REMOVAL [01/2019 - 11/2022]

  21. DISCONNECT ENGINE WIRE 
    1. Disconnect the transmission wire connector.
      GTY919426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Park/Neutral Position Switch Connector *b Transmission Wire Connector
      *c Transmission Revolution Sensor (NIN) Connector *d Transmission Revolution Sensor (NOUT) Connector
      *e Oil Pressure Sensor Connector - -
    2. Disconnect the transmission revolution sensor (NIN) connector.
    3. Disconnect the park/neutral position switch connector.
    4. Disconnect the transmission revolution sensor (NOUT) connector.
    5. Disconnect the oil pressure sensor connector.
    6. Disengage the 5 clamps.
    7. Remove the bolt to disconnect the engine wire from the continuously variable transaxle assembly.
    8. Remove the bolt to disconnect the engine wire from the No. 1 transmission control cable bracket.
    9. Disengage the 3 clamps to disconnect the engine wire from the front suspension crossmember sub-assembly.
      GTY943519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT WATER BY-PASS HOSE 
    1. Slide the 2 clips and disconnect the water by-pass hose from the transmission oil cooler.
      GTY921198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Water By-pass Hose
    2. Disengage the clamp to separate the water by-pass hose from the continuously variable transaxle assembly.
  23. REMOVE STARTER ASSEMBLY 

    Refer to REMOVAL [09/2022 - 11/2022]

  24. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Remove the 2 bolts and No. 1 transmission control cable bracket from the continuously variable transaxle assembly.
      GTY916800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 40

  26. INSTALL ENGINE HANGERS 

    Refer to PROCEDURE - Step 41

  27. DISCONNECT NO. 3 RADIATOR HOSE 

    Refer to PROCEDURE - Step 10

  28. INSTALL ENGINE SUPPORT BRIDGE 
    1. Remove the clip and disconnect the inlet hose from the vehicle body.
      GTY943515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install SST to the vehicle body as shown in the illustration.
      GTY852123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Support Shaft *b Front Side Member
      *c Nut *d Cloth
      • SST: 09940-10020 
      WARNING:
      • Make sure that no oil or grease is on the front side member, and set the support shaft on the level surface of the front side member.
        GTY614759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Support Shaft
        *b Front Side Member
      • The engine support bridge may fall off if any oil or grease is still on or it is installed on the unlevel surface.
      NOTE:
      • Prevent SST from contacting the vehicle body exterior and windshield glass.
      • To prevent damage to the engine hood, place pieces of cloth between the engine hood and SST.
      • Lightly shake SST by hand to make sure it is securely installed before performing work.
    3. Turn the threaded portion of each support shaft to adjust its height until the sub beams are parallel to the ground.
      GTY649983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Support Shaft
      *b Sub Beam
      *c Front Side Member
      *d Threaded Portion
    4. Install the chain block assembly to the sling bracket.
      GTY930220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block Assembly *b Sling Bracket
      *c Fuse Shackle - -
    5. Install the division bar to the chain block assembly with the shackle (A).
      GTY876259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:
      • Make sure the fuse shackle is on the chain block assembly side and the shackle (A) is on the division bar side as shown in the illustration so that the fuse bolt is visible and can be checked for deformation easily.
        GTY668065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuse Shackle
        *b Shackle (A)
      • If the fuse shackle is installed upside down, deformation of the fuse bolt will not be visible and cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with transaxle assembly may fall.
      • Make sure that the fuse bolt of the fuse shackle is free of damage, such as deformation or cracks. If damaged, replace the fuse shackle.
        GTY631927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuse Shackle
        *b Fuse Bolt
      • If a deformed fuse bolt is used, it cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with transaxle assembly may fall.
    6. Connect the division bar to the No. 1 engine hanger with the shackle (B).
      GTY861591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *a Division Bar *b Shackle (B)
      *c Chain *d Shackle (A)
    7. Connect the division bar to the No. 2 engine hanger with the shackle (A) and chain.
      NOTE:

      Connect the 1st link of the chain to the No. 2 engine hanger.

    8. Make sure the distance between the chain block assembly and suspension ring is 120 mm (4.72 in.) or more.
      GTY899812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 120 mm (4.72 in.) or more

      HINT: 

      If the suspension height is less than 120 mm, adjust the links of the chain which connect the division bar and engine hanger.

    9. Adjust the positions of the chain block assembly, support brackets and main beam so that the chain of the chain block assembly is perpendicular to the main beam and the length of the main beam on the outer side of the support bracket LH and RH is the same as shown in the illustration.
      GTY908464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block Assembly *b Main Beam
      *c Dimension (A) *d Dimension (B)
      *e Right to Left Adjustment *f Front to Rear Adjustment
      WARNING:
      • To prevent the engine assembly with transaxle assembly from falling, make sure that the length of dimension (A) and dimension (B) are equal.
        GTY871697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Main Beam
        *b Sub Beam
        *c Dimension (A)
        *d Dimension (B)
      • Do not perform any procedures if the length of dimension (A) and dimension (B) are not equal.
      • Performing any procedure when the length of dimension (A) and dimension (B) are not equal may cause the engine assembly with transaxle assembly and engine support bridge to fall, possibly causing serious injury.
      NOTE:
      GTY832088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not perform any procedures if the chain of the chain block assembly is not straight.
      • When removing the engine mount, if the chain of the chain block assembly is not straight, the engine assembly or transaxle assembly may contact the vehicle body.
    10. Confirm the appropriate installation state of the engine support bridge and tighten the 6 wing bolts and 2 bolts.
      GTY933019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wing Bolt *b Bolt

      Bolt 

      Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

      WARNING:
      • Do not perform any procedures before tightening the bolts to the specified torque.
        GTY638600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Performing procedures without tightening the bolts to the specified torque, may cause the engine support bridge to fall.
    11. Tighten the chain block assembly until it cannot be moved any further by hand.
      GTY873085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      WARNING:
      GTY647185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 41 N.m (418 kgf/cm, 30 ft.lbf) or more
      • When suspending the engine assembly with transaxle assembly, do not tighten the chain block assembly more than 41 N.m (418 kgf/cm, 30 ft.lbf).
      • Tightening the chain block assembly more than 41 N.m (418 kgf/cm, 30 ft.lbf) will cause the load capacity (400 kg (881.8 lb)) to be exceeded and may cause damage to the engine support bridge and vehicle body.
  29. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  30. REMOVE COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 13

  31. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 14

  32. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  33. REMOVE FLYWHEEL HOUSING UNDER COVER 

    Refer to PROCEDURE - Step 34

  34. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 
    1. Turn the crankshaft to gain access to the 6 drive plate and torque converter assembly setting bolts and remove each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.
      GTY916804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      There will be one black colored drive plate and torque converter assembly setting bolt.

  35. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  36. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 11

  37. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the bolt and separate the No. 2 engine moving control rod.
      GTY916790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Support the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.
      GTY885264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Lifter
      *b Attachment
      Attachment placement location
      WARNING:
      • 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.
      GTY916799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Use attachments to keep the front suspension crossmember sub-assembly level.

    3. Remove the 4 bolts and front suspension crossmember sub-assembly.
      GTY943518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Slowly lower the front suspension crossmember sub-assembly.
      NOTE:

      When lowering the front suspension crossmember sub-assembly, be careful not to damage the vehicle body or other components installed to the vehicle.

  38. REMOVE NO. 2 ENGINE MOVING CONTROL ROD 
    1. Remove the 4 bolts and No. 2 engine moving control rod from the continuously variable transaxle assembly.
      GTY916798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY 
    1. Using a transmission jack, support the continuously variable transaxle assembly.
      GTY915182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lashing Belt
      NOTE:
      • 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.
  40. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket LH.
      GTY916769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      While holding the nut in place, loosen the bolt.

    2. Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle body.
      GTY943511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE ENGINE MOUNTING STAY LH 
    1. Remove the 2 bolts and engine mounting stay LH from the continuously variable transaxle assembly and engine mounting bracket LH.
      GTY916817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE ENGINE MOUNTING BRACKET LH 
    1. Remove the 3 bolts and engine mounting bracket LH from the continuously variable transaxle assembly.
      GTY943522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY 
    1. Remove the 7 bolts and continuously variable transaxle assembly from the engine assembly.
      GTY856213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      To prevent damage to the 2 knock pins, do not pry between the continuously variable transaxle assembly and engine assembly.

      HINT: 

      • Bolt (A): Remove from the continuously variable transaxle assembly side.
      • Bolt (B): Remove from the engine assembly side.
  44. REMOVE TORQUE CONVERTER ASSEMBLY 
    1. Remove the torque converter assembly from the continuously variable transaxle assembly.
      GTY916811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Remove the torque converter assembly from the input shaft horizontally.

  45. REMOVE NO. 1 WATER HOSE CLAMP BRACKET 
    1. Remove the clamp from the No. 1 water hose clamp bracket.
      GTY916815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the hose clamp from the No. 1 water hose clamp bracket.
      GTY916812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and No. 1 water hose clamp bracket from the continuously variable transaxle assembly.
      GTY916814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 3 bolts and 3 wire harness clamp brackets from the continuously variable transaxle assembly.
      GTY916813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE STRAIGHT SCREW PLUG 

    HINT: 

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

    1. Remove the straight screw plug and gasket from the continuously variable transaxle assembly.
      GTY943521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE CVT OIL PUMP TYPE T OIL SEAL 
    NOTE:
    • Do not remove the front oil pump assembly from the CVT main body, as there is a possibility of the entry of dust and foreign matter.
    • Clean the work area, the tools to be used, and other equipment, etc. thoroughly before the operation, as there is the possibility that a CVT malfunction, which could prevent the vehicle from being able to be driven, could occur if dust or fine foreign matter enters the CVT.
    • Do not use cotton work gloves, cloths, or paper towels, etc. that may produce lint, dust or foreign matter.
    • Perform the operation as quickly as possible, as dust and foreign matter could enter the CVT while the torque converter assembly is removed.
    • Do not use an air gun until the torque converter assembly has been installed, as it could cause dust and foreign matter to be stirred up.
    1. Clean the tips of both the claws of SST and the center bolt.
      • SST: 09308-10010 
    2. Using SST, remove the CVT oil pump type T oil seal.
      GTY879130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Pay attention to the angle of the claws when opening them, and ensure that they do not come into contact with the oil pump housing, as there is the possibility that metal particles could be produced if they do.

  49. INSPECT TORQUE CONVERTER ASSEMBLY 

    See step  1

  50. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

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