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Home >> Toyota >> 2024 >> Corolla LE >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle System (K120 / K121) - Service Information (2 Of 5) >> Continuously Variable Transaxle Assembly >> Removal [11/2022 - 03/2023] >> Procedure

Removal [11/2022 - 03/2023]: Procedure

  1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  2. DRAIN ENGINE COOLANT (for Fully Sealed Type) 

    Refer to PROCEDURE - Step 1

  3. DRAIN ENGINE COOLANT (for Non-Fully Sealed Type) 

    Refer to PROCEDURE - Step 2

  4. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [11/2022 - 03/2023]

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2022 - ]

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

    Refer to PROCEDURE - Step 3

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 
    1. Remove the 9 bolts, 4 nuts and outer cowl top panel sub-assembly.
      GTY904752Courtesy 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) 

  8. REMOVE ECM 

    Refer to REMOVAL [11/2022 - 03/2023]

  9. REMOVE BATTERY 

    Refer to REMOVAL [11/2022 - ]

  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 18

  11. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 1

  12. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 2

  13. REMOVE FRONT FLOOR CENTER BRACE 

    Refer to PROCEDURE - Step 3

  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 
  15. REMOVE STARTER ASSEMBLY 

    Refer to REMOVAL [11/2022 - ]

  16. DISCONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE 

    Refer to PROCEDURE - Step 4

  17. DISCONNECT ENGINE WIRE 
    1. Remove the bolt and 2 nuts to disconnect the engine wire from the engine assembly.
      GTY874158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Camshaft Position Sensor Connector
      *b Engine Coolant Temperature Sensor Connector
    2. Disconnect the camshaft position sensor connector.
    3. Disconnect the engine coolant temperature sensor connector.
    4. Remove the bolt to disconnect the engine wire from the continuously variable transaxle assembly.
      GTY1114996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the 2 clamps to disconnect the engine wire from the wire harness clamp bracket.
    6. Disengage the claw, rotate the lever and disconnect the transmission wire connector.
      GTY1110361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Transmission Wire Connector *b Shift Stroke Sensor Connector
      *c Park/Neutral Position Switch Connector *d Transmission Revolution Sensor (NOUT) Connector
      *e TCM Connector *f Transmission Revolution Sensor (NSS) Connector
      *g Oil Pressure Sensor Connector *h Transmission Revolution Sensor (NT) Connector
      Remove in this Direction - -
    7. Disconnect the shift stroke sensor connector.
    8. Disconnect the park/neutral position switch connector.
    9. Disconnect the transmission revolution sensor (NOUT) connector.
    10. Disengage the claw, rotate the lever and disconnect the TCM connector.
    11. Disconnect the transmission revolution sensor (NSS) connector.
    12. Disconnect the oil pressure sensor connector.
    13. Disconnect the transmission revolution sensor (NT) connector.
    14. Remove the 2 bolts to disconnect the engine wire from the continuously variable transaxle assembly.
    15. Disengage the 4 clamps to disconnect the engine wire from the wire harness clamp bracket and No. 1 transmission control cable bracket.
    16. Disengage the 3 clamps to disconnect the engine wire from the wire harness clamp bracket.
      GTY876255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE TCM 
    NOTE:

    To prevent coolant from entering the TCM through its connector portion, be sure to remove the TCM before disconnecting any of the coolant system hoses.

    1. Remove the 2 bolts and TCM from the continuously variable transaxle assembly.
      GTY801117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT NO. 2 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 6

  20. DISCONNECT INLET WATER HOSE 

    Refer to PROCEDURE - Step 7

  21. REMOVE FUEL DELIVERY GUARD 

    Refer to PROCEDURE - Step 43

  22. INSTALL ENGINE HANGER 

    Refer to PROCEDURE - Step 44

  23. INSTALL ENGINE SUPPORT BRIDGE 
    1. Remove the clip and disconnect the inlet hose from the vehicle body.
      GTY934549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install SST (engine support bridge) to the vehicle body as shown in the illustration.
      GTY915178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Support Shaft *b Front Side Member
      *c Nut *d Cloth
      • SST: 09940-10020 
      WARNING:
      • Make sure that the front side member is free of oil and other foreign matter and that the support shaft is set toward the outer side of the front side member.
        GTY873655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Support Shaft
        *b Front Side Member
      • If oil or other foreign matter is attached to the front side member or the support shaft is set on the inner side of the front side member, SST (engine support bridge) may fall.
      NOTE:
      • Prevent SST (engine support bridge) 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 (engine support bridge).
      • Lightly shake SST (engine support bridge) 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.
      GTY944482Courtesy 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).
      GTY846028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *a Division Bar *b Shackle (A)
      *c Shackle (B) *d Chain
    7. Connect the division bar to the No. 2 engine hanger with the shackle (A) and chain.
      NOTE:

      Connect the 2nd 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.
      GTY852059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 120 mm (4.72 in.) or more

      HINT: 

      If the suspension height is less than 120 mm (4.72 in.), 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.
      GTY853328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block Assembly *b Main Beam
      *c Dimension (A) *d Dimension (B)
      *e Right to Left Adjustment *f Support Bracket LH
      *g Support Bracket RH *h 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.
        GTY871698Courtesy 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:
      • Do not perform any procedures if the chain of the chain block assembly is not straight.
        GTY832088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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.
      GTY858466Courtesy 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.
      GTY879400Courtesy 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.
  24. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  25. REMOVE COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 13

  26. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 14

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

    Refer to PROCEDURE - Step 5

  28. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 17

  29. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 18

  30. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the bolt and separate the engine moving control rod.
      GTY876441Courtesy 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.
      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.
      GTY876444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

      GTY885992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Lifter
      *b Attachment
      Attachment placement location
    3. Remove the 4 bolts and front suspension crossmember sub-assembly from the vehicle body.
      GTY876443Courtesy 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.

  31. REMOVE NO. 2 ENGINE MOVING CONTROL ROD 
    1. Remove the 5 bolts and No. 2 engine moving control rod from the continuously variable transaxle assembly.
      GTY934591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY 
    1. Using a transmission jack, support the continuously variable transaxle assembly.
      GTY910995Courtesy 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.
      • Using a lashing belt or a rope, fix the continuously variable transaxle assembly to the transmission jack.
  33. REMOVE MANIFOLD STAY 
  34. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and drive shaft heat insulator sub-assembly from the cylinder block sub-assembly.
      GTY975508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Disengage the 2 claws and guide to remove the flywheel housing under cover from the cylinder block sub-assembly.
      GTY879820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  36. 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.
      GTY848071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  37. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the through bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket LH.
      GTY1024396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      While holding the nut in place, loosen the through bolt.

    2. Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle body.
      GTY1024394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY 
    1. Remove the 8 bolts and continuously variable transaxle assembly from the engine assembly.
      GTY880960Courtesy 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), (B): Remove from the continuously variable transaxle assembly side.
      • Bolt (C): Remove from the engine assembly side.
  39. REMOVE TORQUE CONVERTER ASSEMBLY 
    1. Remove the torque converter assembly from the continuously variable transaxle assembly.
      GTY848308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Remove the torque converter assembly from the input shaft horizontally.

    2. Drain the fluid inside the torque converter assembly (when the torque converter assembly is reusable)
      1. When reusing the torque converter assembly, temporarily leave the torque converter assembly with the drive plate and ring gear sub-assembly installation surface facing up for 1 or 2 hours to drain out any fluid remaining in the torque converter assembly.

        HINT: 

        Due to the structure, it is not possible to completely discharge all the fluid.

  40. REMOVE TRANSAXLE HOUSING TYPE T OIL SEAL 
    NOTE:
    • 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 transaxle housing type T oil seal.
      GTY812710Courtesy 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 transaxle housing, as there is the possibility that metal particles could be produced if they do.

  41. REMOVE ENGINE MOUNTING BRACKET LH 
    1. Remove the 6 bolts and engine mounting bracket LH from the continuously variable transaxle assembly.
      GTY1024589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 5 bolts and 5 wire harness clamp brackets from the continuously variable transaxle assembly.
      GTY1114992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. 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.
      GTY848064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE TRANSMISSION CASE PLUG ASSEMBLY 
    1. Remove the transmission case plug assembly from the continuously variable transaxle assembly.
      GTY917771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A
      *B Type B
    2. Remove the O-ring from the transmission case plug assembly.
  45. REMOVE BREATHER PLUG SUB-ASSEMBLY 

    HINT: 

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

    1. GTY801125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the breather plug sub-assembly from the continuously variable transaxle assembly.

    2. Remove the breather plug cap from the breather plug.
      GTY880107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Breather Plug Cap
      *2 Breather Plug
      *3 O-ring
    3. Remove the O-ring from the breather plug.
  46. INSPECT TORQUE CONVERTER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  47. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

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