LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2007 >> Corolla CE, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (1ZZ-FE) >> Engine Assembly >> Removal

Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (See PRECAUTION ).
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. REMOVE FRONT WHEELS 
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE ENGINE UNDER COVER LH 
  6. REMOVE CYLINDER HEAD COVER NO.2 
    1. Remove the cylinder head cover No. 2 (See )REMOVAL .
  7. DRAIN ENGINE COOLANT 
    1. Drain the engine coolant (See ON-VEHICLE INSPECTION ).
  8. DISCONNECT RADIATOR HOSE INLET 
  9. DISCONNECT RADIATOR HOSE OUTLET 
  10. DISCONNECT OIL COOLER INLET HOSE NO.1 (for Automatic Transaxle) 
  11. DISCONNECT OIL COOLER OUTLET HOSE NO.1 (for Automatic Transaxle) 
  12. REMOVE RADIATOR ASSEMBLY (w/ Air Conditioning System) 
    1. Remove the radiator assembly (See REMOVAL ).
  13. REMOVE BATTERY 
  14. REMOVE BATTERY TRAY 
  15. REMOVE BATTERY CARRIER 
    1. Remove the 4 bolts, then remove the battery carrier.
  16. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 
    1. Remove the air cleaner cap sub-assembly (See REMOVAL ).
    Fig 1: Locating Battery Carrier Bolts
    G05194247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Disconnect the clamp [A] of the engine wire.
    2. Remove the 3 bolts [B] from the air cleaner case.
    3. Disconnect the air cleaner case from the air cleaner inlet No. 1 [C].
    Fig 2: Locating Air Cleaner Case Bolts
    G05192941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tube sub-assembly (See REMOVAL ).

      SST 09268-21010 

  19. DISCONNECT UNION TO CHECK VALVE HOSE 
  20. DISCONNECT HEATER INLET WATER HOSE 
    1. Disconnect the heater inlet water hose from the air conditioner tube.
    Fig 3: Locating Heater Inlet Water Hose Clamp
    G05192942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Disconnect the heater outlet water hose from the air conditioner tube.
  22. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Separate the transmission control cable assembly (See REMOVAL ).
  23. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Separate the transmission control cable assembly (See REMOVAL ).
    Fig 4: Locating Heater Outlet Water Hose Clamp
    G05192943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Separate clutch release cylinder assembly (See REMOVAL ).
  25. REMOVE FAN AND GENERATOR V BELT 
    1. Remove the fan and generator V belt (See )ENGINE .
  26. REMOVE GENERATOR ASSEMBLY 
    1. Remove the generator assembly (See REMOVAL ).
  27. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System) 
    1. Separate the compressor and magnetic clutch (See DISASSEMBLY ).

    HINT:

    Secure the compressor and hoses off to the side instead of discharging the A/C system.

  28. SEPARATE RETURN TUBE SUB-ASSEMBLY 
    1. Separate the vane pump oil reservoir from the oil reservoir bracket.
    2. Remove the 2 bolts, then separate the return tube.
    Fig 5: Locating Return Tube Bolts
    G05192944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY 
    1. Remove the glove compartment door assembly (See REMOVAL ).
  30. REMOVE FRONT DOOR SCUFF PLATE RH 
    1. Remove the front door scuff plate RH (See REMOVAL ).
  31. REMOVE COWL SIDE TRIM BOARD RH 
    1. Remove the cowl side trim board RH (See REMOVAL ).
  32. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the ECM and junction block.
    2. Pull out the engine wire.
    3. Remove the engine room relay block cover.
    4. Disconnect the 3 connectors [D].
    5. Disconnect the engine wire harness by pulling it upward [E].
      Fig 6: Locating Connectors [D]
      G05192945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the clamp of the engine wire.
      Fig 7: Locating Engine Wire Clamp
      G05192946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt, then disconnect the ground terminal.
  33. REMOVE FLOOR PANEL BRACE FRONT 
    1. Remove the floor panel brace front (See REMOVAL ).
  34. REMOVE EXHAUST PIPE ASSEMBLY FRONT 
    1. Remove the exhaust pipe assembly front (See REMOVAL ).
  35. REMOVE COLUMN HOLE COVER SILENCER SHEET 
    Fig 8: Locating Ground Terminal Bolt
    G05192947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. SEPARATE STEERING INTERMEDIATE SHAFT 
    1. Separate the steering intermediate shaft (See REMOVAL ).
  37. REMOVE FRONT AXLE HUB LH NUT 
    1. Remove the front axle hub LH nut (See REMOVAL ).

      SST 09930-00010 

  38. REMOVE FRONT AXLE HUB RH NUT 

    SST 09930-00010 

    HINT:

    Perform the same procedure as above on the opposite side.

  39. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 
    1. Separate the front stabilizer link assembly LH (See REMOVAL ).
  40. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  41. SEPARATE SPEED SENSOR FRONT LH (w/ ABS) 
    1. Separate the speed sensor front (See REMOVAL ).
  42. SEPARATE SPEED SENSOR FRONT RH (w/ ABS) 

    HINT:

    Perform the same procedure as above on the opposite side.

  43. SEPARATE TIE ROD END SUB-ASSEMBLY LH 
    1. Separate the tie rod end sub-assembly LH (See REMOVAL ).

      SST 09628-62011 

  44. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    SST 09628-62011 

    HINT:

    Perform the same procedure as above on the opposite side.

  45. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH 
    1. Separate the front suspension arm sub-assembly lower No. 1 LH (See REMOVAL ).
  46. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  47. SEPARATE FRONT AXLE ASSEMBLY LH 
    1. Separate the front axle assembly LH (See REMOVAL ).
  48. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  49. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH.
      Fig 9: Locating Engine Mounting Insulator RH Bolts And Nuts
      G05192770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the through bolt and nut, then separate the engine mounting insulator LH.
      Fig 10: Locating Engine Mounting Insulator LH Bolt And Nut
      G05192949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 6 bolts as shown in the illustration.
    5. Carefully remove the engine with transaxle from the engine compartment.
      Fig 11: [Locating Engine With Transaxle Frame Bolts]
      G05192950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the engine hanger (12281 -22021) with the bolt (91512-B1016 or 90080-10161).

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

    7. Install the engine hanger (12281-15050) with the bolt (91512-B1016 or 90080-10161).

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

      HINT:

      Securely install the front engine hanger (12281-22021) and the rear engine hanger (12281-15050) onto the engine assembly.

      Fig 12: Identifying Engine Hanger With Bolt
      G05192951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Attach the engine sling and hang the engine with the chain block.
  50. SEPARATE VANE PUMP ASSEMBLY 
    1. Separate the vane pump assembly (See REMOVAL ).
  51. REMOVE FRONT SUSPENSION CROSSMEMBER W/ CENTER MEMBER 
    1. Remove the through bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR.
      Fig 13: Locating Engine Mounting Insulator FR Bolt
      G05192952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the through bolt, then separate the engine mounting insulator RR from the engine mounting bracket RR.
    3. Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
  52. REMOVE STARTER ASSEMBLY 
    1. Remove the starter assembly (See DISASSEMBLY ).
  53. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the manual transaxle assembly (See REMOVAL ).
    Fig 14: Locating Engine Mounting Insulator RR Bolt
    G05192953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 
    1. Remove the automatic transaxle assembly (See REMOVAL ).
  55. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) 
    1. Remove the clutch cover assembly (See REMOVAL ).
  56. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 
    1. Remove the clutch disc assembly (See REMOVAL ).
  57. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Remove the flywheel sub-assembly (See REMOVAL ).

      SST 09960-10010 (09962-01000, 09963-01000) 

  58. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Remove the drive plate & ring gear sub-assembly (See REMOVAL ).

      SST 09960-10010 (09962-01000, 09963-01000) 

  59. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the ignition coil assembly (See )REMOVAL .
  60. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Remove the fuel delivery pipe sub-assembly (See REMOVAL ).
  61. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 
  62. REMOVE INTAKE MANIFOLD 
    1. Remove the intake manifold (See REMOVAL ).
  63. REMOVE OIL LEVEL GAUGE GUIDE 
    1. Disconnect the crankshaft position sensor clamp.
    2. Remove the bolt, then remove the oil level gauge guide.
    Fig 15: Locating Oil Level Gage Guide Bolt
    G05192954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE WATER bypass PIPE NO.1 
    1. Disconnect the knock sensor clamp.
    2. Remove the 2 bolts and 2 nuts, then remove the water bypass pipe No. 1.
    3. Remove the gasket from the cylinder block.
  65. REMOVE WATER INLET 
    1. Remove the water inlet (See REMOVAL ).
  66. REMOVE THERMOSTAT 
  67. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Remove the engine oil pressure switch assembly (See ON-VEHICLE INSPECTION ).
    Fig 16: Locating Water bypass Pipe No. 1 Bolts And Nuts
    G05192955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt, then remove the camshaft position sensor.
    Fig 17: Locating Camshaft Position Sensor Bolt
    G05192956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the 2 bolts, then remove the crankshaft position sensor.
    Fig 18: Locating Crankshaft Position Sensor Bolts
    G05192957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE KNOCK SENSOR 
    1. Remove the nut, then remove the knock sensor.
  71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the V-ribbed belt tensioner assembly (See )REMOVAL .
    Fig 19: Locating Knock Sensor Nut
    G05192958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE MANIFOLD STAY 
    1. Remove the 3 bolts and manifold stay.
    Fig 20: Locating Manifold Stay Bolts
    G05192959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Disconnect the air fuel ratio sensor connector [A].
    2. Remove the 4 bolts [B], then remove the exhaust manifold heat insulator.
    Fig 21: Locating Exhaust Manifold Heat Insulator Bolts
    G05192960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE EXHAUST MANIFOLD 
    1. Remove the 5 nuts, then remove the exhaust manifold.
    2. Remove the gasket from the cylinder head.
    Fig 22: Locating Gasket And Exhaust Manifold Nuts
    G05192961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the engine coolant temperature sensor.

      SST 09817-33190 

    Fig 23: Locating Engine Coolant Temperature Sensor
    G05192962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE RADIO SETTING CONDENSER 
    1. Remove the bolt, then remove the condenser.
  77. REMOVE WATER bypass HOSE NO.2 
  78. REMOVE RADIATOR HOSE INLET 
  79. REMOVE HEATER INLET WATER HOSE 
  80. REPLACE PARTIAL ENGINE ASSEMBLY 
Fig 24: Locating Condenser Bolt
G05192963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals