Removal and Replacement

CVT Assembly Dismounting and Remounting
Reference: CVT Assembly Components

WARNING:
Be sure to keep CVT assembly with torque converter horizontal or facing up throughout the work. Torque converter should be tilted to avoid fall it off. Otherwise, personal injury may occur.

CAUTION:
When replacing CVT assembly, all learned controls which are stored in TCM memory should be erased after the replacement. Neglecting this initialization may cause excessive shift shock.

Dismounting
1) Remove bolts (1) fastening engine and CVT assembly.





2) Dismount CVT assembly with engine.
3) Remove front drive shafts.
4) For 4WD model, remove transfer.
5) For 2WD model, remove drive intermediate shaft.
6) Remove drive plate cover.
7) Remove torque converter No.1 and No.2 bolt as follows.
a) Insert flat-end screwdriver or the like (2) to hole (3) of CVT assembly as shown in figure.
b) Lock drive plate (1), engage a flat-end screwdriver or the like with gear of drive plate as shown in figure.
c) Remove torque converter No.1 or No.2 bolt through drive plate cover opening.
d) Turn crankshaft by 60° by turning crankshaft pulley bolt using wrench.
e) Repeat Step a) through c) 5 times.








8) Remove starting motor.
9) Remove the following parts.
^ Front mounting bracket
^ Rear mounting
^ Engine rear mounting bracket No.1
^ Engine rear mounting bracket No.2
10) Remove bolts and nut fastening engine and CVT assembly, and then detach CVT assembly from engine.

CAUTION:
When detaching CVT assembly from engine, move it in parallel with crankshaft and be careful not to apply excessive force to drive plate and torque converter.

Remounting
1) Make sure that torque converter is installed correctly to CVT assembly.
2) Attach CVT assembly to engine.
3) Tighten bolts and nut to specified torque.
4) Install the following parts.
^ Front mounting bracket
^ Rear mounting
^ Engine rear mounting bracket No.1
^ Engine rear mounting bracket No.2
5) Tighten torque converter No.1 and No.2 bolts as follows.

NOTE:
Torque converter No.1 bolt is used for accurate positioning.
Tighten torque converter No.1 bolt first so that bolt holes for torque converter and drive plate are positioned properly, and that torque converter No.2 bolt is tightened securely.
One torque converter No.1 bolt and five torque converter No.2 bolts are required to secure torque converter and drive plate.

a) Align bolt hole of drive plate with bolt hole of torque converter by turning crankshaft.
b) Insert flat-end screwdriver or the like (2) to hole (3) of CVT assembly as shown in figure.
c) Lock drive plate (1), engage a flat-end screwdriver or the like with gear of drive plate as shown in figure.








d) Tighten torque converter No.1 bolt to 5 Nm (0.51 kgf-m, 4.0 lbf-ft) through starting motor opening.
e) Turn crankshaft by 60° and tighten torque converter No.2 bolts by hand through starting motor opening.
f) Tighten torque converter No.1 bolt to specified torque.

Tightening torque
Torque converter No.1 bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)

g) Turn crankshaft by 60° and tighten torque converter No.2 bolts to specified torque.

Tightening torque
Torque converter No.2 bolt (a): 23 Nm (2.3 kg-m, 17.0 lbf-ft)





6) Install starting motor.
7) Install drive plate cover.
8) For 2WD model, install drive intermediate shaft.

CAUTION:
Be careful not to scratch oil seal lip with center shaft while installing.

9) For 4WD model, install transfer.
10) Install front drive shaft.
11) Remount engine with CVT assembly to vehicle.
12) Tighten engine fastening bolts (1) and CVT assembly to specified torque.





13) Refill CVT fluid.
14) Check CVT fluid level.
15) After installation, check for CVT fluid leakage at each connection.
16) After replacing CVT assembly, perform learning control initialization.