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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical (2ZR-FAE) - Service Information (1 Of 2) (Model Code: ZRE172)) >> Engine Assembly & Engine Under Cover >> Removal [08/2013 - 08/2016] >> Procedure

Removal [08/2013 - 08/2016]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    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 [08/2013 - 08/2015] Refer to PRECAUTION [08/2015 - 08/2016]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [08/2013 - 08/2016]

  3. PLACE 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 [08/2013 - 08/2015] Refer to INITIALIZATION [08/2015 - 08/2016]

  5. REMOVE FRONT WHEEL 
  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 

    Refer to PROCEDURE - Step 5

  11. 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.
      GTY429880Courtesy 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.

  12. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  13. 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.
  14. REMOVE BATTERY 
    1. Loosen the nut, and disconnect the cable from the positive (+) battery terminal.
      GTY432591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
  15. 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.
      GTY432594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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
  17. 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
  18. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 12

  19. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the duty vacuum switching valve.
      GTY429101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Slide the clip and disconnect the union to connector tube hose from the air tube.
      GTY433247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT HEATER WATER OUTLET HOSE 

    Refer to PROCEDURE - Step 5

  22. DISCONNECT HEATER WATER INLET HOSE 

    Refer to PROCEDURE - Step 6

  23. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disengage the claw and remove the No. 1 fuel pipe clamp.
      GTY426005Courtesy 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 fuel tube sub-assembly.
      • Protect the disconnected parts 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.
  24. REMOVE V-RIBBED BELT 

    See step  4

  25. REMOVE GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 5

  26. REMOVE NO. 2 GENERATOR BRACKET 
    1. Remove the bolt and No. 2 generator bracket.
      GTY433391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Disconnect the 2 connectors.
      GTY429100Courtesy 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 and separate the compressor assembly with pulley.

      HINT: 

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

      GTY429102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 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. Remove the bolt and disconnect the clamp and No. 3 engine wire from the continuously variable transaxle assembly.
      GTY430588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to REMOVAL [08/2013 - ]

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

    Refer to REMOVAL [08/2013 - ]

  31. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [08/2013 - 08/2016]

  32. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover.
      GTY440971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 3 Refer to PROCEDURE - Step 3

  34. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  35. 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 bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH.
      GTY194436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the through bolt and nut, and separate the engine mounting insulator LH.
      GTY454051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts and center engine mounting member sub-assembly.
      GTY431123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Carefully remove the engine assembly with transaxle from the vehicle.
  36. 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 and nut, and separate the front engine mounting insulator from the front engine mounting bracket.
      GTY432587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  37. 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 rear engine mounting insulator from the rear engine mounting bracket.
      GTY432588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. 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.
      GTY433014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. 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. GTY432902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 3 bolts and engine mounting insulator sub-assembly RH.

  40. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the bolt and wire harness clamp bracket.
      GTY444738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL ENGINE HANGER 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.
      GTY442262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger (Part No. 12281-37050)
      *2 No. 2 Engine Hanger (Part No. 12282-37040)
      *3 Bolt (Part No. 91552-81050)

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

    2. Attach an engine sling device and hang the engine assembly with a chain block.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.
      • 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.
  42. REMOVE HEATER WATER OUTLET HOSE 
    1. Slide the clip and remove the heater water outlet hose from the No. 1 water by-pass pipe.
      GTY430394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE HEATER WATER INLET HOSE 
    1. Slide the clip and remove the heater water inlet hose from the cylinder head sub-assembly.
      GTY430395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. DISCONNECT WATER BY-PASS HOSE ASSEMBLY 
    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
  45. 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
  46. REMOVE STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 5 Refer to PROCEDURE - Step 5

  47. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly with transaxle.
  48. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 22 Refer to PROCEDURE - Step 22

  49. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2 See step  2 See step  2

  50. 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.
  51. REMOVE ENGINE HANGER 
    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
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