LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2ZR-FE) - Service Information (1 Of 2) (Model Code: ZRE172) >> Engine Assembly & Engine Under Cover >> Removal [08/2016 - ] >> Procedure

Removal [08/2016 - ]: Procedure

  1. PRECAUTION 
    WARNING:

    The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

    NOTE:
    • 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 notices before proceeding with work.

      Refer to PRECAUTION [08/2016 - ]

    • for Manual Transaxle:

      When the manual transaxle is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release with bearing cylinder assembly to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [08/2016 - ]

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [08/2016 - 08/2017] Refer to INITIALIZATION [08/2017 - ]

  5. REMOVE FRONT WHEELS 
  6. REMOVE ENGINE UNDER COVER LH 
    1. Remove the 2 bolts, 2 screws, 3 clips and engine under cover LH.
  7. REMOVE ENGINE UNDER COVER RH 
    1. Remove the 3 bolts, 2 screws, 4 clips and engine under cover RH.
  8. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  9. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  10. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT) 

    Refer to PROCEDURE - Step 5

  11. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    Refer to PROCEDURE - Step 2

  12. REMOVE NO. 2 CYLINDER HEAD COVER 
    1. Lift the rear of the No. 2 cylinder head cover to disengage the 2 rear clips. Lift the front of the No. 2 cylinder head cover to disengage the 2 front clips and remove the No. 2 cylinder head cover.
      GTY437725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Disengage the 2 rear clips first
      Disengage the 2 front clips next
      NOTE:

      Attempting to disengage both front and rear clips at the same time may cause the No. 2 cylinder head cover to break.

  13. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
      GTY450897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the wire harness clamp from the air cleaner case sub-assembly.
      GTY430389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and air cleaner case sub-assembly.
  15. REMOVE BATTERY 
    GTY432591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Loosen the nut, and disconnect the cable from the positive (+) battery terminal.
    2. Remove the bolt and nut.
    3. Remove the battery clamp sub-assembly.
    4. Remove the battery and battery tray from the battery carrier.
    5. Remove the battery clamp bolt from the battery carrier support.
      GTY446820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Battery Clamp Bolt
      *2 Battery Carrier Support
  16. REMOVE BATTERY CARRIER 
    1. Disconnect the 2 wire harness clamps from the battery carrier.
      GTY432593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and disconnect the radiator pipe from the battery carrier.
      GTY438571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts and battery carrier.
      GTY432878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disconnect the breather plug hose from the clamp.
      GTY433015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.
      GTY438579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY438582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT) 

    Refer to PROCEDURE - Step 12

  20. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the 2 clips (A) and disconnect the 2 transmission control cable assemblies from the manual transaxle assembly.
      GTY433948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 clips (B) and disconnect the 2 transmission control cable assemblies from the control cable bracket.
  21. DISCONNECT CLUTCH HOSE (for Manual Transaxle) 
    1. Using a 10 mm union nut wrench, disconnect the clutch hose from the flexible hose tube.
      GTY432880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clip and disconnect the clutch hose.
  22. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV)
      GTY432874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Slide the clip and disconnect the union to connector tube hose from the air tube.
      GTY452376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT OUTLET HEATER WATER HOSE (for CVT) 
    1. Slide the clip and disconnect the outlet heater water hose from the air conditioner unit assembly.
      GTY436911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the outlet heater water hose from the No. 1 water by-pass pipe.
  25. DISCONNECT OUTLET HEATER WATER HOSE (for Manual Transaxle) 
    1. Slide the clip and disconnect the outlet heater water hose from the No. 1 water by-pass pipe.
      GTY437088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT INLET HEATER WATER HOSE 

    Refer to PROCEDURE - Step 6

  27. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disengage the claw and remove the No. 1 fuel pipe clamp.
      GTY438755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the retainer as shown in the illustration, then pull the fuel tube connector off the fuel pipe.
      GTY161592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter to get on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the fuel pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, kink or twist the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube sub-assembly.
      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.
  28. REMOVE V-RIBBED BELT 

    See step  4

  29. REMOVE GENERATOR ASSEMBLY (for 115A Type) 

    Refer to PROCEDURE - Step 5

  30. REMOVE GENERATOR ASSEMBLY (for 100A Type) 

    Refer to PROCEDURE - Step 5

  31. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Disconnect the connector.
      GTY434953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp.
    3. Remove the 2 bolts and 2 nuts.
      GTY451554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

      HINT: 

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

      GTY429102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Separate the compressor assembly with pulley from the engine assembly.
  32. DISCONNECT WIRE HARNESS 
    1. Pull up the lever and disconnect the ECM connector.
      GTY455087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the wire harness clamp.
    3. Remove the No. 1 engine room relay block cover from the engine room relay block and junction block assembly.
    4. Remove the 2 nuts from the engine room relay block and junction block assembly.
      GTY445459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the 3 wire harness connectors.
    6. Disengage the 2 claws and disconnect the wire harness from the engine room relay block and junction block assembly.
    7. for CVT:
      1. Remove the bolt and disconnect the clamp and No. 3 engine wire from the continuously variable transaxle assembly.
        GTY430588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. for Manual Transaxle:
      1. Remove the bolt and disconnect the No. 3 engine wire from the manual transaxle assembly.
        GTY433374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disconnect all the wire harnesses and connectors.

      HINT: 

      Make sure that no wire harness is connected between the vehicle body and engine assembly.

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

    Refer to REMOVAL [08/2013 - ]

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

    Refer to REMOVAL [08/2013 - ]

  35. REMOVE DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [08/2016 - ]

  36. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover from the stiffening crankcase assembly.
      GTY440832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT) 

    Refer to PROCEDURE - Step 3

  38. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  39. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set an engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.
      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
      • Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.
    2. Remove the center engine mounting member sub-assembly.

      Refer to PROCEDURE - Step 17

    3. Remove the bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH.
      GTY432903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the through bolt, nut and engine mounting insulator LH.

      HINT: 

      Because the nut has its own stopper, do not turn the nut. Loosen the through bolt with the nut secured.

      GTY693667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for CVT
      *B for Manual Transaxle
    5. Carefully remove the engine assembly with transaxle from the vehicle.
      NOTE:

      Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

  40. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.

    1. Remove the through bolt, nut and front engine mounting insulator.

      HINT: 

      Because the nut has its own stopper, do not turn the nut. Loosen the through bolt with the nut secured.

      GTY687881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for CVT
      *B for Manual Transaxle
  41. REMOVE REAR ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    1. Remove the through bolt and separate the rear engine mounting insulator.
      GTY700699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for CVT
      *B for Manual Transaxle
  42. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

    1. Remove the 4 bolts and engine mounting insulator LH.
      GTY695613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Remove the 3 bolts and engine mounting insulator sub-assembly RH.
      GTY432902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE WIRE HARNESS CLAMP BRACKET 
    GTY428544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the clamp and wire harness.
    2. Remove the bolt and wire harness clamp bracket.
  45. INSTALL ENGINE HANGER 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.
      GTY442078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger (Part No. 12281-37021)
      *2 No. 2 Engine Hanger (Part No. 12282-37011)
      *3 Bolt (Part No. 91552-81050)

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

    2. Attach an engine sling device and hang the engine assembly with a chain block.
      NOTE:
      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  46. DISCONNECT WATER BY-PASS HOSE ASSEMBLY (for CVT) 
    1. Slide the clip and disconnect the water by-pass hose assembly from the No. 1 water by-pass pipe.
      GTY438374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE FLYWHEEL HOUSING SIDE COVER 
    1. Push up the flywheel housing side cover as shown in the illustration to disengage the claw, and remove the flywheel housing side cover.
      GTY436872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protruding Portion
  48. REMOVE STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  49. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly with transaxle.
  50. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT) 

    Refer to PROCEDURE - Step 22

  51. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT) 

    See step  3

  52. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    Refer to PROCEDURE - Step 7

  53. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transaxle) 

    Refer to PROCEDURE - Step 3

  54. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle) 

    Refer to PROCEDURE - Step 4

  55. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle) 

    Refer to PROCEDURE - Step 5

  56. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle) 

    Refer to PROCEDURE - Step 6

  57. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) 

    Refer to PROCEDURE - Step 7

  58. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 

    Refer to PROCEDURE - Step 8

  59. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 

    See step  4

  60. INSTALL ENGINE TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.
      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.
  61. REMOVE ENGINE HANGER 
    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
scientia non olet · About LEMON Manuals