Toyota CH-R Service Manual: Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the continuously variable transaxle assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or Procedure

Necessary Procedure

Effect/Inoperative when not Performed

Link

Disconnect cable from negative battery terminal

Initialize back door lock

Power door lock control system

Memorize steering angle neutral point

Lane departure alert system (w/ Steering Control)

Pre-collision system

  • Air leaks from intake system
  • Gas leaks from exhaust system

Inspection After Repair

  • Poor idle, etc.
  • Engine start function, etc.

Replacement of CVT fluid

ATF thermal degradation estimate reset

The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

Replacement of continuously variable transaxle assembly

Perform the following procedures in the order shown:

  1. Reset memory
  2. Deceleration sensor zero point calibration
  3. CVT oil pressure calibration

Deterioration of fuel efficiency

Front wheel alignment adjustment

Perform the following procedures in the order shown:

  1. Clear zero point calibration data and store system information
  2. Perform yaw rate and acceleration sensor zero point calibration and store system information
  • DTCs are stored
  • ABS warning light illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)

Initialize No. 1 headlight ECU sub-assembly LH

Automatic headlight beam level control system

CAUTION:

  • Because the continuously variable transaxle assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

    *a

    Heavy object exceeding the capacity of the transmission jack

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the transmission jack could drop and components could fall down.
  • When the engine is hot, do not touch high-temperature areas such as the engine or exhaust pipe.
  • Touching high-temperature areas such as the engine and exhaust pipe could result in burns.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work.

Click here

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click here

NOTICE:

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

Click here

3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

4. REMOVE FRONT WHEELS

Click here

5. REMOVE NO. 1 ENGINE UNDER COVER

Click here

6. REMOVE REAR ENGINE UNDER COVER LH

Click here

7. REMOVE REAR ENGINE UNDER COVER RH

Click here

8. DRAIN ENGINE COOLANT

Click here

9. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID

Click here

10. REMOVE WINDSHIELD WIPER MOTOR AND LINK

Click here

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

Click here

12. REMOVE WATER GUARD PLATE LH

Click here

13. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

Click here

14. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

Click here

15. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

16. REMOVE BATTERY

Click here

17. REMOVE NO. 2 CYLINDER HEAD COVER

Click here

18. REMOVE RADIATOR COVER

Click here

19. REMOVE NO. 1 AIR CLEANER INLET

Click here

20. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Click here

21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Click here

22. REMOVE ECM

Click here

23. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Remove the bolt and nut to separate the engine wire from the battery clamp sub-assembly.

(b) Disengage the clamp to separate the engine wire from the battery clamp sub-assembly.

(c) Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

24. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut to disconnect the transmission control cable assembly from the control shaft lever.

(b) Remove the clip to disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.

(c) Remove the nut to disconnect the transmission control cable assembly from the transmission control cable support.

25. DISCONNECT NO. 3 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 3 water by-pass hose from the oil cooler.

26. DISCONNECT NO. 5 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 5 water by-pass hose from the oil cooler.

(b) Disconnect the No. 5 water by-pass hose from the 2 clamps.

27. DISCONNECT ENGINE WIRE

(a) Disconnect the park/neutral position switch connector.

*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) Disconnect the transmission wire connector.

(c) Disconnect the transmission revolution sensor (NIN) connector.

(d) Disconnect the transmission revolution sensor (NT) connector.

(e) Disconnect the transmission revolution sensor (NOUT) connector.

(f) Disconnect the oil pressure sensor connector.

(g) Remove the 3 bolts and nut to disconnect the engine wire from the continuously variable transaxle assembly.

(h) Disengage the 5 clamps to disconnect the engine wire from the continuously variable transaxle assembly.

28. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Disconnect the clamp from the No. 1 transmission control cable bracket.

(b) Remove the 2 bolts and No. 1 transmission control cable bracket from the continuously variable transaxle assembly.

29. SECURE STEERING WHEEL ASSEMBLY

Click here

30. REMOVE COLUMN HOLE COVER SILENCER SHEET

Click here

31. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

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

Click here

33. REMOVE FRONT FLOOR COVER LH (w/ Cover)

Click here

34. REMOVE FRONT FLOOR COVER RH (w/ Cover)

HINT:

Use the same procedure as for the LH side.

35. REMOVE FRONT FLOOR CENTER BRACE

Click here

36. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

Click here

37. REMOVE FRONT DRIVE SHAFT ASSEMBLIES

Click here

38. INSTALL ENGINE HANGER

(a) Disengage the 5 clamps.

(b) Disconnect the air fuel ratio sensor connector.

(c) Remove the bolt and wire harness clamp bracket.

(d) Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

*1

No. 1 Engine Hanger

*2

No. 2 Engine Hanger

Bolt

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

No. 1 Engine Hanger

12281-37070

No. 2 Engine Hanger

12282-37060

Bolt

91552-81050

39. INSTALL ENGINE SUPPORT BRIDGE

(a) Remove the clip and the neck from the windshield washer jar assembly.

(b) Install SST to the vehicle body as shown in the illustration.

*a

Support Shaft

*b

Front Side Member

*c

Front Suspension Nut

-

-

SST: 09940-10020

CAUTION:

  • 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.

    *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.

NOTICE:

  • 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.

(c) Turn the threaded portion of each support shaft to adjust its height until the sub beams are parallel to the ground.

*a

Support Shaft

*b

Sub Beam

*c

Front Side Member

*d

Threaded Portion

(d) Install the chain block to the sling bracket.

*a

Chain Block

*b

Sling Bracket

*c

Fuse Shackle

*d

Shackle (A)

(e) Install the division bar to the chain block with the shackles.

CAUTION:

  • Make sure the fuse shackle is on the chain block 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.

    *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 automatic 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.

    *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.

(f) Connect the division bar to the No. 1 engine hanger with the shackle (A) and chain.

*1

No. 1 Engine Hanger

*2

No. 2 Engine Hanger

*a

Division Bar

*b

Shackle (A)

*c

Chain

-

-

NOTICE:

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

(g) Connect the division bar to the No. 2 engine hanger with the shackle (A) and chain.

NOTICE:

Connect the 2nd link of the chain to the No. 2 engine hanger.

(h) Make sure the distance between the chain block assembly and suspension ring is 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.

*a

120 mm (4.72 in.) or more

(i) 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.

*a

Chain Block Assembly

*b

Main Beam

*c

Dimension (A)

*d

Dimension (B)

*e

Right to Left Adjustment

*f

Front to Rear Adjustment

CAUTION:

  • To prevent the engine with automatic transaxle assembly from falling, make sure that the length of dimension (A) and dimension (B) are equal.
  • Do not perform any procedures if the length of dimension (A) and dimension (B) are not equal.

    *a

    Main Beam

  • Performing any procedure when the length of dimension (A) and dimension (B) are not equal may cause the engine assembly with automatic transaxle assembly and engine support bridge to fall, possibly causing serious injury.

(j) Confirm the appropriate installation state of the engine support bridge and tighten the 6 wing bolts and 2 bolts.

*a

Wing Bolt

*b

Bolt

Torque:

Bolt :

30 N·m {306 kgf·cm, 22 ft·lbf}

CAUTION:

  • Do not perform any procedures before tightening the bolts to the specified torque.
  • Performing procedures without tightening the bolts to the specified torque, may cause the engine support bridge to fall.

(k) Tighten the chain block assembly until it cannot be moved any further by hand.

*a

Turn

*a

41 N*m (418 kgf*cm, 30 ft.*lbf) or more

  • When suspending the engine with automatic 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.

40. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

Click here

41. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

Click here

42. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Click here

43. REMOVE NO. 2 ENGINE MOVING CONTROL ROD

(a) Remove the 4 bolts and No. 2 engine moving control rod from the continuously variable transaxle assembly.

44. SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

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

NOTICE:

  • 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.

*a

Lashing Belt

45. REMOVE STARTER ASSEMBLY

Click here

46. REMOVE FLYWHEEL HOUSING SIDE COVER

Click here

47. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the flywheel housing under cover.

48. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

(a) 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.

HINT:

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

49. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR

(a) Remove the bolt and nut to separate the engine mounting insulator LH from the transverse engine engine mounting bracket.

(b) Remove the nut and 4 bolts.

(c) Remove the engine mounting insulator LH from the vehicle body.

50. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

(a) Remove the 5 bolts and transverse engine engine mounting bracket from the continuously variable transaxle assembly.

51. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

(a) Remove the 8 bolts and continuously variable transaxle assembly from the engine assembly.

NOTICE:

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

52. REMOVE TORQUE CONVERTER ASSEMBLY

(a) Remove the torque converter assembly from the continuously variable transaxle assembly.

NOTICE:

Remove the torque converter assembly from the input shaft horizontally.

53. REMOVE CVT OIL PUMP TYPE T OIL SEAL

CAUTION:

  • Do not remove the front oil pump assembly from the continuously variable transaxle assembly 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 continuously variable transaxle assembly malfunction, which may prevent the vehicle from being driven, may occur if dust or fine foreign matter enters the continuously variable transaxle assembly.
  • Do not use cotton work gloves, cloths, paper towels, etc. that may produce lint, dust or foreign matter.
  • Perform the operation as quickly as possible, as dust and foreign matter may enter the continuously variable transaxle assembly while the torque converter assembly is not attached to it.
  • Do not use an air gun until the torque converter assembly has been installed, as it may cause dust and foreign matter to be stirred up.

(a) Clean the tips of both the claws of SST and the center bolt.

SST: 09308-10010

(b) Using SST, remove the CVT oil pump type T oil seal from the continuously variable transaxle assembly.

NOTICE:

Pay attention to the angle of the claws of SST 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 may be produced if they do.

*1

CVT Oil Pump Type T Oil Seal

*a

Claw

54. REMOVE TRANSMISSION CONTROL CABLE SUPPORT

(a) Remove the 2 bolts and transmission control cable support from the continuously variable transaxle assembly.

55. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the bolt and water hose clamp bracket from the continuously variable transaxle assembly.

*1

Wire Harness Clamp Bracket

*2

Water By-pass Hose Clamp

*3

Water Hose Clamp Bracket

(b) Remove the water by-pass hose clamp from the water hose clamp bracket.

(c) Remove the 3 bolts and 3 wire harness clamp brackets from the continuously variable transaxle assembly.

56. REMOVE TUBE CONNECTOR

(a) Slide the clip and disconnect the No. 1 transmission oil cooler hose from the tube connector.

NOTICE:

Do not damage the coating of the hose insertion part of the tube connector.

(b) Remove the tube connector from the continuously variable transaxle assembly.

(c) Remove the O-ring from the tube connector.

57. REMOVE OIL COOLER ELBOW SUB-ASSEMBLY

(a) Slide the clip and disconnect the No. 2 transmission oil cooler hose from the oil cooler elbow sub-assembly.

NOTICE:

Do not damage the coating of the hose insertion part of the oil cooler elbow sub-assembly.

(b) Remove the union bolt, oil cooler elbow sub-assembly and gasket from the continuously variable transaxle assembly.

58. REMOVE AUTOMATIC TRANSMISSION CASE COVER

(a) Remove the 2 clips and automatic transmission case cover from the continuously variable transaxle assembly.

59. REMOVE STRAIGHT SCREW PLUG

HINT:

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

(a) Remove the straight screw plug and gasket from the continuously variable transaxle assembly.

60. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

HINT:

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

(a) Remove the transmission breather hose sub-assembly from the continuously variable transaxle assembly.

*1

Transmission Breather Hose Sub-assembly

(b) Remove the No. 1 breather plug (CVT) and No. 2 breather plug (CVT) from the breather plug hose.

*1

No. 1 Breather Plug (CVT)

*2

Breather Plug Hose

*3

No. 2 Breather Plug (CVT)

*4

O-ring

(c) Remove the O-ring from the breather plug.

61. INSPECT TORQUE CONVERTER ASSEMBLY

Click here

62. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

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