Primary Pulley And Secondary Pulley: Installation

NOTE:

When replacing the primary pulley and secondary pulley, always replace them as a set.
When replacing the primary pulley, secondary pulley and variator chain, always replace them as a set.

Install a new seal ring.
NOTE:
- Apply CVTF to the seal rings.
- Do not stretch the seal ring more than necessary.
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When replacing the primary pulley and secondary pulley, select the primary pulley shim.

Using the ST, measure the height "H1" from the ST end face to the primary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

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Measure the height "H2" from the ST end face to the secondary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

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Using the following calculation and selection criteria table, select an appropriate thickness of the primary pulley shim.

NOTE: Adjust using 1 - 2 pieces.

C = B - A + H1 - H2 - 31.137 mm (1.2259 in)

Pulley alignment mm (in)

Measured value (mm (in)) of step (1)

Measured value (mm (in)) of step (2)

Specified primary pulley dimension⁽¹⁾

Specified secondary pulley dimension⁽¹⁾

31.137 mm (1.2259 in)

Constant

⁽¹⁾	The specified dimensions of the primary pulley and secondary pulley are stamped only on repair parts.

PRIMARY PULLEY SHIM SELECTION CRITERIA FOR CALCULATED VALUES

Pulley alignment mm (in)	Thickness of primary pulley shim mm (in)
-0.007 - 0.049 (-0.0003 - 0.002)	No shims
0.050 - 0.149 (0.002 - 0.006)	0.1 (0.004)
0.150 - 0.249 (0.006 - 0.010)	0.2 (0.008)
0.250 - 0.349 (0.010 - 0.014)	0.3 (0.012)
0.350 - 0.449 (0.014 - 0.018)	0.4 (0.016)
0.450 - 0.549 (0.018 - 0.022)	0.5 (0.020)
0.550 - 0.649 (0.022 - 0.026)	0.6 (0.024)
0.650 - 0.749 (0.026 - 0.029)	0.7 (0.028)
0.750 - 0.849 (0.029 - 0.033)	0.8 (0.031)
0.850 - 0.949 (0.033 - 0.037)	0.9 (0.035)
0.950 - 1.049 (0.037 - 0.041)	1.0 (0.039)
1.050 - 1.149 (0.041 - 0.045)	1.1 (0.043)
1.150 - 1.163 (0.045 - 0.046)	1.2 (0.047)

Install the secondary pulley.

Temporarily install the secondary pulley.

NOTE:

Apply CVTF to the threaded portion of the bolts and seat surface.
Be careful not to tilt the bearing retainer.
Tighten the bolt (a) to the position where any part of the seat surface contacts.

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Tighten the bolts in the numerical order as shown in the figure.
Tightening torque:

67.5 N.m (6.9 kgf-m, 49.8 ft-lb)

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Set the variator chain to the secondary pulley.

Using the ST, expand the chain groove of the secondary pulley.

When using EXPANDER PULLEY (18769AA030)

Preparation tool:

ST: EXPANDER PULLEY (18769AA030)

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When replacing EXPANDER PULLEY (18769AA010) and LOCK PLATE (16047AA000)
Preparation tool:

ST1: EXPANDER PULLEY (18769AA010)

ST2: LOCK PLATE (16047AA000)

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Install the primary pulley.

Set the primary pulley shim.

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Intersect the chain groove of primary pulley and the chain groove of secondary pulley, and set the primary pulley while placing the variator chain on the primary pulley.

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Align the bolt hole of primary bearing retainer and the bolt hole of reverse brake housing, and install the bolt to secure the primary pulley.
NOTE: Apply CVTF to the threaded portion of the bolts and seat surface.

Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

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Install the chain guide.

Install the chain guide (B) to the variator chain (A).

Place the support rod (C) on the variator chain inside and install the chain guide (B).

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Install the bolt securing the support rod.

NOTE: Apply CVTF to the threaded portion of the bolts and seat surface.

Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

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Install the chain guide (B) to the variator chain (A).

Place the lubrication pipe (C) on the variator chain inside and install the chain guide (B).

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Install the bolt to secure the lubrication pipe.

NOTE: Apply CVTF to the threaded portion of the bolts and seat surface.

Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

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Remove the ST (EXPANDER PULLEY).
NOTE: When LOCK PLATE (16047AA000) was used, restore EXPANDER PULLEY (18769AA010) to its original state.

Install the reduction drive gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>REDUCTION DRIVE GEAR>INSTALLATION .