Toyota CH-R Service Manual: Installation

INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

HINT:

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

(a) Apply Toyota Genuine CVT fluid FE to a new O-ring, and install it to the No. 2 breather plug (CVT).

NOTICE:

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

(b) Install the No. 1 breather plug (CVT) and No. 2 breather plug (CVT) to the breather plug hose.

(c) Install the transmission breather hose sub-assembly to the continuously variable transaxle assembly.

2. INSTALL STRAIGHT SCREW PLUG

HINT:

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

(a) Install a new gasket and the straight screw plug to the continuously variable transaxle assembly.

Torque:

16.2 N·m {165 kgf·cm, 12 ft·lbf}

3. INSTALL AUTOMATIC TRANSMISSION CASE COVER

(a) Install the automatic transmission case cover to the continuously variable transaxle assembly with the 2 clips.

4. INSTALL OIL COOLER ELBOW SUB-ASSEMBLY

(a) Install a new gasket and oil cooler elbow sub-assembly to the continuously variable transaxle assembly with the union bolt.

Torque:

22.6 N·m {230 kgf·cm, 17 ft·lbf}

(b) Install the No. 2 transmission oil cooler hose to the oil cooler elbow sub-assembly and slide the clip to secure it.

5. INSTALL TUBE CONNECTOR

(a) Install a new O-ring to the tube connector.

(b) Install the tube connector to the continuously variable transaxle assembly.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

(c) Install the No. 1 transmission oil cooler hose to the tube connector and slide the clip to secure it.

6. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 3 wire harness clamp brackets to the continuously variable transaxle assembly with the 3 bolts. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

*1 Wire Harness Clamp Bracket *2 Water By-pass Hose Clamp *3 Water Hose Clamp Bracket

(b) Install the water by-pass hose clamp to the water hose clamp bracket.

(c) Install the water hose clamp bracket to the continuously variable transaxle assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

7. INSTALL TRANSMISSION CONTROL CABLE SUPPORT

(a) Install the transmission control cable support to the continuously variable transaxle assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

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.

NOTICE:

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

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

SST: 09309-36010

(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. Standard depth: 0 to 0.5 mm (0 to 0.0196 in.) 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 0.0196 in.) as measured from the side surface of the oil pump housing.

*a 0 to 0.5 mm (0 to 0.0196 in.)

9. INSTALL TORQUE CONVERTER ASSEMBLY

(a) Turn the front oil pump drive gear so that the wide groove is at the top and place a matchmark on the transaxle housing. NOTICE: Align the matchmark with the wide groove of the transaxle housing.

*a Matchmark

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

*a Key *b Matchmark

(c) Align the matchmark on the transaxle 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.

*1 CVT Oil Pump Type T Oil Seal *a Matchmark

(d) 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.

*1 CVT Oil Pump Type T Oil Seal *a Matchmark

(e) Rotate the torque converter assembly approximately 180° again, align the matchmark on the torque converter assembly with the one on the transaxle housing and insert the key of the torque converter assembly into the groove of the oil pump drive gear. NOTICE: 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 oil pump type T oil seal.

*1 CVT Oil Pump Type T Oil Seal *a Matchmark

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

(g) 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.

*a Engine Assembly Surface *b Drive Plate Surface

(h) 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. Standard: B = 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.

10. SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

(a) Using a transmission jack, support the continuously variable transaxle assembly.

11. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

(a) 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.)

*1 Crankshaft *a Torque Converter Assembly Centerpiece

(b) Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.

(c) Install the continuously variable transaxle assembly to the engine assembly with the 8 bolts.

Torque:

Bolt (A) :

38 N·m {387 kgf·cm, 28 ft·lbf}

Bolt (B) :

40 N·m {408 kgf·cm, 30 ft·lbf}

12. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

(a) Install the transverse engine engine mounting bracket with the 5 new bolts. Torque: 41 N·m {418 kgf·cm, 30 ft·lbf}

*a Temporarily Tighten

13. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR

(a) Temporarily install the transverse engine engine mounting insulator to the vehicle body with the nut and 4 bolts.

*a Temporarily Tighten

(b) Fully tighten the nut and 4 bolts in the order shown in the illustration.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

(c) Install the transverse engine engine mounting insulator to the transverse engine engine mounting bracket with the bolt and nut. Torque: 44 N·m {449 kgf·cm, 32 ft·lbf} NOTICE: Turn the bolt while holding the nut.

14. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

(a) Using SST, hold the crankshaft pulley.

SST: 09213-54015

SST: 09330-00021

HINT:

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

(b) Clean the threads of the 6 drive plate and torque converter assembly setting bolts.

(c) 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.

*a Adhesive

(d) 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.

Torque:

41 N·m {418 kgf·cm, 30 ft·lbf}

NOTICE:

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

15. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover.

16. INSTALL FLYWHEEL HOUSING SIDE COVER

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17. INSTALL STARTER ASSEMBLY

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18. INSTALL NO. 2 ENGINE MOVING CONTROL ROD

(a) Install the No. 2 engine moving control rod to the continuously variable transaxle assembly with the 4 bolts in the order shown in the illustration. Torque: 44 N·m {449 kgf·cm, 32 ft·lbf}

*a Temporarily Tighten

19. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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20. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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21. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

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22. REMOVE ENGINE SUPPORT BRIDGE

(a) Remove SST from the vehicle body.

NOTICE:

Prevent SST from contacting the vehicle body or windshield glass.

(b) Install the neck from the windshield washer jar assembly with the clip.

23. REMOVE ENGINE HANGER

(a) Remove the 2 bolts and No. 2 engine hanger from the cylinder head.

(b) Remove the 2 bolts and No. 1 engine hanger from the cylinder head.

(c) Install the wire harness clamp bracket with the bolt. Torque: 39 N·m {398 kgf·cm, 29 ft·lbf}

(d) Connect the air fuel ratio sensor connector.

(e) Engage the 5 clamps.

24. INSTALL FRONT DRIVE SHAFT ASSEMBLIES

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25. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

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26. INSTALL FRONT FLOOR CENTER BRACE

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27. INSTALL FRONT FLOOR COVER LH (w/ Cover)

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28. INSTALL FRONT FLOOR COVER RH (w/ Cover)

HINT:

Use the same procedure as for the LH side.

29. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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30. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

31. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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32. INSTALL COLUMN HOLE COVER SILENCER SHEET

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33. 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}

(b) Connect the clamp to the No. 1 transmission control cable bracket.

34. CONNECT ENGINE WIRE

(a) Engage the 5 clamps to connect the engine wire to the continuously variable transaxle assembly.

*1	Park/Neutral Position Switch Connector	*2	Transmission Wire Connector
*3	Transmission Revolution Sensor (NIN) Connector	*4	Transmission Revolution Sensor (NOUT) Connector
*5	Transmission Revolution Sensor (NT) Connector	*6	Oil Pressure Sensor Connector

(b) Connect the engine wire to the continuously variable transaxle assembly with the 3 bolts and nut.

Torque:

Bolt (A) :

8.5 N·m {87 kgf·cm, 75 in·lbf}

Bolt (B) :

8.0 N·m {82 kgf·cm, 71 in·lbf}

Nut :

8.0 N·m {82 kgf·cm, 71 in·lbf}

(c) Connect the oil pressure sensor connector.

(d) Connect the transmission revolution sensor (NOUT) connector.

(e) Connect the transmission revolution sensor (NIN) connector.

(f) Connect the transmission revolution sensor (NT) connector.

(g) Connect the transmission wire connector.

(h) Connect the park/neutral position switch connector.

35. CONNECT NO. 3 WATER BY-PASS HOSE

(a) Connect the No. 3 water by-pass hose to the oil cooler, and slide the clip to secure it.

36. CONNECT NO. 5 WATER BY-PASS HOSE

(a) Connect the No. 5 water by-pass hose to the oil cooler, and slide the clip to secure it.

37. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install the transmission control cable assembly to the transmission control cable support with the nut. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(b) Turn the control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

*a P Position *b N Position

(c) Install the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(d) Connect the transmission control cable assembly to the control shaft lever with the nut.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

38. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the air battery clamp sub-assembly to the vehicle with the 3 bolts.

Torque:

15.4 N·m {157 kgf·cm, 11 ft·lbf}

(b) Engage the clamp to connect the engine wire to the battery clamp sub-assembly.

(c) Connect the engine wire to the battery clamp sub-assembly with the bolt and nut.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

39. INSTALL ECM

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40. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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41. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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42. INSTALL NO. 1 AIR CLEANER INLET

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43. INSTALL RADIATOR COVER

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44. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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45. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

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46. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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47. INSTALL WATER GUARD PLATE LH

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48. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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49. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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50. INSTALL FRONT WHEELS

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51. INSTALL BATTERY

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52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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53. ADD ENGINE COOLANT

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54. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

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55. INSPECT FOR COOLANT LEAK

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56. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK

57. INSPECT FOR EXHAUST GAS LEAK

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HINT:

Perform "Inspection After Repairs" after repairing or replacing the exhaust system.

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58. INSPECT SHIFT LEVER POSITION

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59. ADJUST SHIFT LEVER POSITION

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60. INSTALL REAR ENGINE UNDER COVER RH

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61. INSTALL REAR ENGINE UNDER COVER LH

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62. INSTALL NO. 1 ENGINE UNDER COVER

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63. INSTALL NO. 2 CYLINDER HEAD COVER

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64. CHECK FOR SPEED SENSOR SIGNAL

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65. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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66. RESET MEMORY

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