How to Replace the Engine on 1999 - 2005 Toyota Corolla / Celica / Echo / MR2 1.8L 4 Cyl Models: Part 2
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How to Replace the Engine on 1999 - 2005 Toyota Corolla / Celica / Echo / MR2 1.8L 4 Cyl Models: Part 2

How to Replace the Engine on 1999 - 2005 Toyota Corolla / Celica / Echo / MR2 1.8L 4 Cyl Models: Part 2.

(Continued from Part 1)

Removal & Installation

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system" or "remove the radiator." In most instances, a detailed removal procedure can be found elsewhere in this product.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:

  • If you have to drain any of the fluids, use a suitable container.
  • Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
  • Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
  • After unbolting the transmission or transaxle, always make sure it is properly supported.
  • If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
  • When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
  • Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
  • After the engine is clear of the compartment, place it on an engine stand or workbench.
  • After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined herein.

The engine and transaxle assembly must be removed as a single unit.

  • Disconnect the negative battery cable. Wait at least 90 seconds after the battery cable is disconnected to hinder air bag deployment.

CAUTION: Work must NOT be started until after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. Never use a back-up power supply from outside the vehicle.

  • Remove the battery.
  • With the aid of an assistant, unbolt and remove the hood.
  • Raise and safely support the front of the vehicle securely on jackstands. Remove the engine undercovers.
  • Drain and recycle the engine coolant.
  • Drain the engine oil from the crankcase.
  • Drain the transaxle case fluid.
  • Disconnect and label any wiring associated with removal of the air cleaner. Unclamp, disconnect the air hose then unbolt and remove the air cleaner assembly.
  • Disconnect the accelerator cable from the throttle body and cable bracket.
  • Disconnect the cruise control actuator cable from its clamps.
  • On Canadian models, disconnect the relay box for the daytime running lights system from the radiator.
  • Remove the radiator. Be sure to label all wiring and hoses and pipes.
  • Disconnect the following wiring:
  1. Manifold Absolute Pressure (MAP) sensor vacuum hose from the gas filter on the intake manifold
  2. Power steering air hose from the intake manifold
  3. Power steering hose from the air pipe
  4. Brake booster vacuum hose from the intake manifold
  5. A/C idle-up valve connector
  6. A/C idle-up valve hose from the intake manifold
  7. A/C idle-up valve hose from the air pipe
  8. Data Link Connector (DLC1) from the bracket
  9. Engine wire protector with bracket
  10. Ground cable and strap from body
  11. 2 heater hoses from the water inlet housing
  12. Fuel inlet hose from the fuel filter
  13. Fuel return hose from return pipe
  14. EVAP hose from charcoal canister
  • Disconnect and labile the engine wire from the engine compartment relay box.
  • Remove the scuff plate, cowl side trim and lower instrument finish panel.
  • Disconnect the engine wire from the clamp of the ECM bracket, the ECM connections, circuit opening relay wiring and A/C amplifier connection.
  • Detach the MAP sensor wiring and separate from the bracket.
  • Unclamp the engine wire from the bracket.
  • Remove the nuts holding the engine wire retainer to the cowl panel.
  • Pull out the engine wire from the cabin.
  • Remove the front exhaust pipe.
  • Remove both driveshafts.
  • Remove the alternator drive belt.
  • Separate, suspend and secure the A/C compressor from the engine but do NOT disconnect any lines.
  • Separate, suspend and secure the power steering pump from the engine but do NOT disconnect any lines.
  • On the 5S-FE engine, remove the starter motor assembly.
  • Remove the bolts, and disconnect the A/C relay box.
  • On manual transaxles, disconnect the clutch slave cylinder.
  • Disconnect the transaxle control cables.
  • On automatics, disconnect the transaxle control cable from the engine mounting center member.
  • Remove the exhaust pipe support bracket.
  • Remove the engine mounting center crossmember two dust covers from the rear.
  1. Disconnect the A/C pipe from the bracket.
  2. Remove the bolt and nut holding the front engine mounting bracket to the mounting insulator.
  3. Remove the bolt holding the rear engine mounting bracket to the mounting insulator.
  4. Remove the bolt and the two nuts holding the rear engine mounting insulator to the front suspension crossmember.
  5. Remove the bolts and the rear engine mounting bracket.
  6. Remove the bolts holding the center member and rear engine mounting insulator.
  • Attach the No. 1 engine hanger in the correct direction. Attach the engine chain hoist to the hanger.

CAUTION: Do NOT attempt to hang the engine by hooking the chain to any other component.

  • Remove the two bolts and nut, then disconnect the LH engine mounting bracket from the insulator. Remove the through bolt and LH engine insulator.
  • Disconnect the ground strap connector. Remove the bolt and nuts, then disconnect the RH engine bracket from the insulator.

Make sure the engine is clear of all wiring, hoses and cables.

  • Place the engine and transaxle assembly onto the stand.
  • Separate the engine from the transaxle.
  • Install and attach all components to the engine and transaxle in the reverse order of removal. Make sure to tighten all components securely, refer the Torque Specifications chart at the end of this section. Pay particular attention the following:
  • Secure the engine to the transaxle and tighten the retaining bolts to:
  1. 12mm-17 ft. lbs. (23 Nm)
  2. 14mm-34 ft. lbs. (46 Nm)
  3. 17mm-47 ft. lbs. (64 Nm)
  • Attach the chain hoist to the engine hangers. Slowly lower the engine assembly into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH body mounting.
  • Keep the engine level, and align the RH and LH mountings with the body mountings.
  • Attach the RH engine mounting bracket to the insulator, then temporarily install the nuts. Temporarily install the LH engine mounting insulator to the body with the through bolt. Attach the LH mounting bracket to the insulator and secure with the bolts and nut. Tighten the through bolt retaining the LH engine mount insulator to the body. Tighten the nuts holding the RH engine mounting bracket to the insulator.
  • Attach the ground strap wiring, remove the engine chain hoist, bolt and engine No. 1 hanger.
  • Install the engine center mounting crossmember. Attach the member together with the rear engine mounting insulator to the front suspension member. Temporarily install the two bolts holding the center member to the body. Install the rear engine mounting bracket with the two bolts. Tighten them to 58 ft. lbs. (78 Nm).
  • Temporarily install the bolt and two nuts holding the rear engine mounting insulator to the front suspension member. Temporarily install the bolt holding the rear engine mounting bracket to the insulator. Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator.
  • Tighten the two bolts holding the center member to the body to 26 ft. lbs. (35 Nm).
  • Tighten the bolt and two nuts holding the rear engine mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm).
  • Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88Nm).
  • Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm). Install and secure all other components.
  • Install the battery.
  • Attach the battery cables.
  • Fill the cooling system, engine crankcase and transaxle with the correct types and amounts of fluids. Start the engine and check for leaks. Perform engine adjustments as necessary.

WARNING: Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  • Install the engine under covers and hood. Road test the vehicle and recheck the fluid levels.

1NZ-FE Engines

  • Before servicing the vehicle, refer to the Precautions section.
  • Drain the cooling system.
  • Drain the engine oil.
  • Drain the transaxle fluid.
  • Remove or disconnect the following:
  1. Hood Battery and tray
  2. Outer front cowl top panel
  3. Engine under covers
  4. Accelerator cable
  5. Air cleaner cap and related parts
  6. Air cleaner case and related parts
  7. All tubes, hoses and connectors attached to the engine
  8. Accessory drive belts
  9. Alternator
  10. Radiator
  11. With A/C, position the compressor out of the way
  12. With MT, the clutch release cylinder
  13. Transaxle control cables
  14. Fusible link
  15. Power steering pump
  16. Center exhaust pipe
  17. Halfshafts Suspension cross member
  18. Rear engine mount
  • Attach a shop crane to the engine hangers.
  • Remove all remaining engine mount bolts/nuts.
  • Remove the engine/transaxle assembly.

To install:

  • Install or connect the following:
  1. Engine/transaxle assembly into position
  2. Right engine mount insulator.
  3. Torque the bolts to 35 ft. lbs. (47 Nm).
  4. Left engine mount.
  5. Torque the bolts to 35 ft. lbs. (47 Nm).
  6. Rear engine mount bracket.
  7. Torque the bolts to 35 ft. lbs. (47 Nm).
  8. Rear engine mount insulator.
  9. Torque the bolt to 47 ft. lbs. (64 Nm).
  10. Suspension cross member.
  11. Torque the rear mount bolts to 86 ft. lbs. (116 Nm); the front mount bolts to 52 ft. lbs. (70 Nm).
  12. Halfshafts
  13. Center exhaust pipe
  14. Power steering pump
  15. Fusible link
  16. Transaxle control cables
  17. Clutch release cylinder.
  18. Torque the 2 bolts to 10 ft. lbs. (13 Nm).
  19. Compressor.
  20. Torque the 4 bolts to 18 ft. lbs. (25 Nm).
  21. Radiator
  22. Alternator
  23. All remaining tubes, hoses and connectors
  24. Air cleaner case
  25. Air cleaner cap
  26. Accelerator cable
  27. Outer front cowl top panel
  28. Engine under covers
  29. Battery and tray
  30. Coolant
  31. Engine oil
  32. Transaxle oil
  33. Hood
  • Start the vehicle, check for leaks and repair if necessary.

1ZZ-FE Engines

  • Before servicing the vehicle, refer to the Precautions section.
  • Relieve the fuel system pressure.
  • Drain the cooling system.
  • Drain the engine oil.
  • Drain the transaxle fluid.
  • Remove or disconnect the following:
  1. Negative battery cable.
  2. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. B
  3. attery
  4. Hood
  5. Undercover
  6. Accelerator cable
  7. With automatic transmission, throttle cable from the accelerator cable.
  8. Radiator and cooling fan
  9. Air cleaner assembly
  10. Coolant reservoir tank stay
  11. Electrical connector, the hose, the mounting bolt, and remove the washer tank
  12. Cruise control actuator
  13. The Manifold Absolute Pressure (MAP) sensor vacuum hose from the gas filter on the intake manifold
  14. The brake booster vacuum hose from the intake manifold With air conditioning: the air conditioning vacuum hose from the actuator
  15. With power steering: the air hose from the air pipe
  16. With air conditioning: the air conditioning actuator connector
  • Disconnect the following wires and connectors from the right-hand fender apron as follows:
  1. The ground strap connector.
  2. The MAP sensor connector.
  3. With air conditioning: the air conditioning pressure switch.
  4. The engine wiring harness from the fender apron.
  • Remove or disconnect the following:
  1. Data Link Connector 1 (DLC1) connector and ground strap from the left-hand fender apron.
  2. Engine relay box and 4 connectors.
  3. Charcoal canister
  4. Heater hoses from water inlet housing
  5. Fuel inlet and return hoses
  6. With manual transmission, clutch release cylinder without disconnecting the pipe
  7. Transaxle control cable(s)
  • To disconnect the engine wiring harness, disconnect or remove the following components:
  1. Left-hand and right-hand front door scuff plate
  2. Lower finish panel
  3. Lower panel with the glove compartment
  4. Radio and center cluster finish panel
  5. Rear console box
  6. On manual transmission, shift lever knob
  7. On automatic transmission, shifting hole bezel
  8. Lower center finish panel
  9. Floor carpet bracket
  10. The 3 ECM connectors and cowl wire connector
  • Remove or disconnect the remaining components:
  1. Air conditioning compressor
  2. Front exhaust pipe
  3. Halfshafts
  4. Power steering pump
  5. Engine mounting center member
  6. Through-bolt and nut holding the mounting insulator to the mounting bracket
  7. Engine and transaxle assembly
  8. Front and rear engine mounting bracket
  9. Starter
  10. Separate the transaxle from the engine

To install:

  • Install or connect the following:
  1. Engine to the transaxle
  2. Starter
  3. Rear engine mounting bracket bolts: 57 ft. lbs. (77 Nm).
  4. Front engine mounting bracket. bolts: 57 ft. lbs. (77 Nm).
  5. Engine and transaxle assembly into the vehicle
  6. Engine mounting center member.
  7. Front engine mounting insulator through-bolt and nut.
  8. Torque the bolt to 64 ft. lbs. (87 Nm).
  9. Halfshafts
  10. Front exhaust pipe
  11. Power steering pump.
  12. Torque the bolts to 29 ft. lbs. (39 Nm).
  13. Drive belt
  14. Air conditioner compressor.
  15. Torque the bolts to 18 ft. lbs. (25 Nm).
  16. Drive belt and reconnect the connector.
  • To install and connect the engine wiring harness, perform the following:
  1. Push the wire through the cowl
  2. Connect the 3 ECM connectors
  3. Attach the cowl wire connector
  4. Floor carpet bracket
  5. Center lower finish panel
  6. With automatic transmission, install the shifting hole bezel, with manual transmission, install the shift lever knob Rear console box
  7. Center cluster finish panel and the radio
  8. Lower panel with the glove compartment door
  9. Right and left-hand door scuff plates
  10. Lower finish panel
  • Install or connect the following:
  1. With manual transmission, clutch release cylinder
  2. Transaxle control cable(s)
  3. Fuel return and inlet hose.
  4. Torque the bolt to 22 ft. lbs. (29 Nm).
  5. Heater hoses to the water inlet housing
  6. Charcoal canister
  • Connect the following wires and connectors on the left-hand fender apron:
  1. The 4 connectors to the engine relay box
  2. Engine relay box
  3. The DLC1 connector
  4. The connector on the fender apron
  5. The ground strap on the fender apron
  • Install or connect on the right-hand fender apron:
  1. The ground strap connector
  2. The MAP sensor connector
  3. With air conditioning, the air conditioning pressure switch
  4. The engine wire from the fender apron
  • Install or connect the following:
  1. With A/C, the actuator connector
  2. With power steering, the air hoses to the air pipe
  3. The vacuum hose from the MAP sensor to the gas filter to the intake chamber
  4. The brake booster vacuum hose to the air intake chamber
  5. With A/C, the vacuum hose from the actuator
  6. With cruise control, actuator, actuator cable and cover
  7. Electrical connector and vinyl hose
  8. Washer tank with the bolt
  9. Coolant reservoir tank stay
  10. Air cleaner
  11. Radiator and cooling fan
  12. With automatic transmission, connect the throttle cable.
  13. Accelerator cable
  14. All fluids
  15. Negative battery cable
  16. Undercovers and hood
  • Start the vehicle, check for leaks and repair if necessary.

Engines

  • Before servicing the vehicle, refer to the Precautions section.
  • Release the fuel system pressure.
  • Drain the engine oil.
  • Drain the cooling system.
  • Drain the transaxle fluid.
  • Remove or disconnect the following:
  1. Negative battery cable.
  2. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  3. Battery
  4. Hood
  5. Undercover
  6. Accelerator cable, cable bracket, and clamps.
  7. Air cleaner
  8. Cruise control actuator cable
  9. Radiator
  10. MAP sensor vacuum hose from the gas filter on the intake manifold
  11. Power steering air hose from the intake manifold
  12. Power steering hose from the air the air pipe
  13. Brake booster vacuum hose from the intake manifold
  14. Air conditioning idle-up valve
  15. Air conditioning idle-up valve hose from the intake manifold
  16. Air conditioning idle-up valve hose from the air pipe DLC1 from the bracket
  17. Engine wiring harness from the bracket
  18. Ground cable from the body and the ground strap from the body
  19. Heater hoses from the water outlet
  20. Heater hose from the water bypass pipe
  21. Fuel inlet hose from the fuel filter and the fuel return hose from the return pipe
  22. EVAP hose from the charcoal canister
  23. Engine wiring harness from the engine compartment relay box
  • To remove the engine wiring harness from the passenger-s compartment, remove or disconnect the following:
  1. The scuff plate
  2. The cowl side trim
  3. The finish panel from the lower instrument panel
  4. Front side of the floor carpet
  5. The wiring harness from the clamp of the ECM bracket
  6. The 3 ECM connectors
  7. The circuit opening relay connector
  8. The 3 connectors from the connectors on the bracket
  9. The A/C amplifier connector
  10. The MAP sensor connector
  11. The MAP sensor wire from the clamp on the bracket
  12. The wire clamp from the bracket
  13. The 2 nuts holding the engine wiring harness to the cowl
  • Remove or disconnect the following:
  1. Front exhaust pipe
  2. Halfshafts
  3. Alternator drive belt
  4. Air conditioning drive belt, compressor connector, and compressor.
  5. Do not disconnect the air conditioning lines
  6. Remove the drive belt and remove the 4 bolts that secure the power steering pump.
  7. Without disconnecting the lines, securely hang the pump out of the way A/C relay box
  8. On manual transmission, clutch release cylinder from the transaxle
  9. Transaxle control cable(s)
  10. On automatic transmission, transaxle control cable from the engine mounting center member.
  11. Exhaust pipe support bracket.
  • To remove the engine mounting center member, remove the following components:
  1. The 2 dust covers from the rear side of the member
  2. The A/C pipe from the bracket
  3. The bolt and nut holding the front engine mounting bracket to the mounting insulator
  4. The bolt holding the rear engine mounting bracket to the insulator
  5. The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member
  6. The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator
  • Remove or disconnect the remaining components:
  1. Attach an engine chain hoist to the engine hangers
  2. Left-hand engine mounting bracket from the mounting insulator
  3. Through-bolt and the left-hand mounting insulator
  4. Ground strap connector
  5. Right-hand engine mounting bracket from the mounting insulator
  6. Lift the engine and transaxle assembly from the vehicle
  7. Transaxle from the engine assembly

To install:

  • Install or connect the following:
  1. Transaxle to the engine assembly.
  2. Engine into the engine compartment
  3. Right-hand engine mounting bracket to the mounting insulator.
  4. Temporarily install the 3 nuts.
  5. Left-hand engine mounting insulator to the body with the through-bolt
  6. Left-hand engine mounting bracket to the mounting insulator and install the 2 bolts and nut.
  7. Bolts and nut: 47 ft. lbs. (64 Nm).
  8. Left-hand engine mounting through-bolt to the body.
  9. Bolt: 54 ft. lbs. (73 Nm).
  10. Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 Nm), 14mm nut: 38 ft. lbs. (52 Nm).
  11. Engine ground strap connector and remove the engine hoist.
  • To install the engine mounting center member, perform the following:
  1. Attach the center member together with the rear engine mounting insulator to the front suspension member
  2. Temporarily install the 2 bolts and nut holding the center member to the body Install the rear engine mounting bracket.
  3. Bolts: 58 ft. lbs. (78 Nm)
  4. Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member
  5. Temporarily install the bolt holding the rear engine mounting bracket to the insulator
  6. Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator
  7. Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm)
  8. Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm)
  9.  Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm)
  10. Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm)
  11. Install the air conditioning pipe to the bracket and install the 2 dust covers to the center member
  • Install or connect the following:
  1. Exhaust pipe support bracket.
  2. Bolts to 14 ft. lbs. (19 Nm).
  3. Transaxle control cable(s)
  4. On automatic transmission, transaxle control cable to the engine mounting center member.
  5. On manual transmission, clutch release cylinder.
  6. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt.
  7. A/C relay box to the body
  8. Power steering pump. 12mm bolts: 14 ft. lbs. (19 Nm). 14mm bolts: 29 ft. lbs. (39 Nm).
  9. Install the drive belt.
  10. Adjusting bolt: 29 ft. lbs. (39 Nm).
  11. A/C compressor.
  12. Bolts: 18 ft. lbs. (25 Nm).
  13. A/C drive belt with the adjusting bolt.
  14. Torque the locknut to 29 ft. lbs. (39 Nm).
  15. Connect the connector.
  16. Alternator drive belt
  17. Halfshafts
  18. Front exhaust pipe
  • To install the engine wiring harness in the passenger compartment, perform the following:
  1. Push the harness through the cowl panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket
  2. Connect the harness to the clamp on the ECM
  3. Connect the 3 ECM connectors and the circuit opening relay connector
  4. Connect the 3 connectors to the connectors on the bracket
  5. Connect the A/C amplifier connector
  6. Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff plate
  • Install or connect the following:
  1. Engine wiring harness with the 2 connectors to the engine compartment relay box and install the relay box covers
  2. MAP sensor connector
  3. MAP sensor wire to the clamp on the bracket
  4. MAP sensor vacuum hose to the gas filter on the intake manifold
  5. Brake booster vacuum hose to the intake manifold
  6. A/C idle-up valve connector
  7. A/C idle-up valve hose to the intake manifold
  8. A/C idle-up valve hose to the air pipe
  9. DLC1 to the bracket
  10. Engine harness protector to the bracket
  11. Ground cable and the ground strap
  12. hose to the water outlet and the heater hose to the water bypass pipe
  13. Fuel inlet hose to the fuel filter
  14. Fuel inlet hose with 2 new gaskets and the union bolt.
  15. Bolt: 22 ft. lbs. (30 Nm).
  16. Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister
  17. Power steering air hoses to the intake manifold and the air pipe
  18. Radiator
  19. Actuator cable to the clamps, on models equipped with cruise control
  20. Accelerator cable to the throttle body, cable bracket, and the clamps
  21. Air cleaner
  22. Battery tray and battery
  23. Hood
  24. Negative battery cable
  25. Engine undercover
  • Refill the transaxle assembly, engine oil and coolant.
  • Start the vehicle, check for leaks and repair if necessary.

Engines

  • Before servicing the vehicle, refer to the Precautions section.
  • Drain the cooling system.
  • Relieve the fuel system pressure.
  • Drain the engine oil
  • Drain the transaxle fluid
  • Remove or disconnect the following:
  1. Engine hood
  2. Rear suspension upper brace
  3. Engine undercovers
  4. Battery and tray
  5. Air cleaner assembly and intake air hose
  6. Accelerator cable
  7. Rear bumper cover
  8. Heated
  9. Oxygen (HO 2 S) sensor connectors
  10. Front exhaust pipe
  11. Accessory drive belt
  12. A/C compressor
  13. Engine wiring harness connectors in the luggage compartment.
  14. Pull the harness through the firewall.
  15. Transaxle control
  16. ECU harness connector
  17. Engine wire at Junction Box No. 1
  18. Engine ground wires
  19. Wire brackets
  20. Heater hoses
  21. Radiator hoses
  22. Fuel line
  23. Clutch hose
  24. Shift cables
  25. Axle halfshafts
  • Support the drivetrain from below.
  1. Left and right motor mounts
  2. Front and rear motor mounts
  3. Rear subframe
  • Lower the drivetrain assembly from the vehicle.
  • Remove the starter.
  • Remove the transaxle flange bolts and separate the engine and transaxle.

To install:

  • Installation is the reverse of the removal procedure, while using the following torque values:
  1. Rear subframe.
  2. Tighten the bolts to 59 ft. lbs. (80 Nm).
  3. Front and rear motor mounts.
  4. Tighten the through bolts to 69 ft. lbs. (93 Nm).
  5. Left and right motor mounts.
  6. Tighten the mounting fasteners to 38 ft. lbs. (52 Nm) and the through bolts to 64 ft. lbs. (87 Nm).
  7. A/C compressor.
  8. Tighten the bolts to 18 ft. lbs. (25 Nm).
  9. Front exhaust pipe.
  10. Tighten the bolts to 32 ft. lbs. (43 Nm) and the nut to 46 ft. lbs. (62 Nm).

2ZZ-GE Engines

  • Before servicing the vehicle, refer to the Precautions section.
  • Release the fuel system pressure.
  • Drain the cooling system.
  • Drain the engine oil.
  • Drain the transaxle fluid.
  • Remove or disconnect the following:
  1. Negative battery cable.
  2. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  3. Battery
  4. Hood
  5. Undercover
  6. Accelerator cable, cable bracket, and clamps.
  7. Air cleaner
  8. ECM box
  9. Cruise control actuator cable
  10. Radiator
  11. MAP sensor vacuum hose from the gas filter on the intake manifold
  12. Power steering air hose from the intake manifold
  13. Power steering hose from the air the air pipe
  14. Brake booster vacuum hose from the intake manifold
  15. A/C idle-up valve
  16. A/C idle-up valve hose from the intake manifold
  17. A/C idle-up valve hose from the air pipe
  18. DLC1 from the bracket
  19. Engine wiring harness from the bracket
  20. Ground cable from the body and the ground strap from the body
  21. Heater hoses from the water outlet
  22. Heater hose from the water bypass pipe
  23. Fuel inlet hose from the fuel filter and the fuel return hose from the return pipe
  24. EVAP hose from the charcoal canister
  25. Engine wiring harness from the engine compartment relay box
  • To remove the engine wiring harness from the passenger-s compartment, remove or disconnect the following:
  1. The scuff plate
  2. The cowl side trim
  3. The finish panel from the lower instrument panel
  4. Remove the front side of the floor carpet
  5. The wiring harness from the clamp of the ECM bracket
  6. The 3 ECM connectors
  7. The circuit opening relay connector
  8. The 3 connectors from the connectors on the bracket
  9. The A/C amplifier connector
  10. The MAP sensor connector
  11. The MAP sensor wire from the clamp on the bracket
  12. The wire clamp from the bracket
  13. The 2 nuts holding the engine wiring harness to the cowl
  • Remove or disconnect the following:
  1. Front exhaust pipe
  2. Exhaust manifold
  3. Halfshafts
  4. Alternator drive belt
  5. A/C drive belt, compressor connector, and compressor.
  6. Do not disconnect the A/C lines
  7. Remove the drive belt and remove the 4 bolts that secure the power steering pump.
  8. Without disconnecting the lines, securely hang the pump out of the way.
  9. A/C relay box
  10. On manual transmission, clutch release cylinder from the transaxle
  11. Transaxle control cable(s)
  12. On automatic transmission, transaxle control cable from the engine mounting center member.
  13. Exhaust pipe support bracket
  • To remove the engine mounting center member, remove the following components:
  1. The 2 dust covers from the rear side of the member
  2. The air conditioning pipe from the bracket
  3. The bolt and nut holding the front engine mounting bracket to the mounting insulator
  4. The bolt holding the rear engine mounting bracket to the insulator
  5. The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member
  6. The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator
  • Remove or disconnect the remaining components:
  1. Attach an engine chain hoist to the engine hangers
  2. Left-hand engine mounting bracket from the mounting insulator
  3. Through-bolt and the left-hand mounting insulator
  4. Ground strap connector
  5. Right-hand engine mounting bracket from the mounting insulator
  6. Lift the engine and transaxle assembly from the vehicle
  7. Transaxle from the engine assembly

To install:

  • Install or connect the following:
  1. Transaxle to the engine assembly
  2. Engine into the engine compartment
  3. Right-hand engine mounting bracket to the mounting insulator.
  4. Temporarily install the 3 nuts.
  5. Left-hand engine mounting insulator to the body with the through-bolt
  6. Left-hand engine mounting bracket to the mounting insulator and install the 2 bolts and nut.
  7. Bolts and nut: 47 ft. lbs. (64 Nm).
  8. Left-hand engine mounting through-bolt to the body.
  9. Bolt: 54 ft. lbs. (73 Nm).
  10. Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 Nm), 14mm nut: 38 ft. lbs. (52 Nm).
  11. Engine ground strap connector and remove the engine hoist
  • To install the engine mounting center member, perform the following:
  1. Attach the center member together with the rear engine mounting insulator to the front suspension member
  2. Temporarily install the 2 bolts and nut holding the center member to the body Install the rear engine mounting bracket.
  3. Bolts: 58 ft. lbs. (78 Nm)
  4. Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member
  5. Temporarily install the bolt holding the rear engine mounting bracket to the insulator
  6. Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator
  7. Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm)
  8. Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm)
  9.  Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm)
  10. Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm)
  11. Install the A/C pipe to the bracket and install the 2 dust covers to the center member
  12. Exhaust manifold
  • Install or connect the following:
  1. Exhaust pipe support bracket.
  2. Bolts to 14 ft. lbs. (19 Nm).
  3. Transaxle control cable(s)
  4. On automatic transmission, transaxle control cable to the engine mounting center member.
  5. On manual transmission, clutch release cylinder.
  6. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt
  7. A/C relay box to the body
  8. Power steering pump. 12mm bolts: 14 ft. lbs. (19 Nm). 14mm bolts: 29 ft. lbs. (39 Nm).
  9. Install the drive belt.
  10. Adjusting bolt: 29 ft. lbs. (39 Nm).
  11. A/C compressor.
  12. Bolts: 18 ft. lbs. (25 Nm).
  13. A/C drive belt with the adjusting bolt and tighten the idler pulley locknut to 29 ft. lbs. (39 Nm).
  14. Connect the connector.
  15. Alternator drive belt
  16. Halfshafts
  17. Front exhaust pipe
  • To install the engine wiring harness in the passenger compartment, perform the following:
  1. Push the harness through the cowl panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket
  2. Connect the harness to the clamp on the ECM
  3. Connect the 3 ECM connectors and the circuit opening relay connector
  4. Connect the 3 connectors to the connectors on the bracket
  5. A/C amplifier connector
  6. Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff plate
  • Install or connect the following:
  1. Engine wiring harness with the 2 connectors to the engine compartment relay box and install the relay box covers.
  2. MAP sensor connector
  3. MAP sensor wire to the clamp on the bracket
  4. MAP sensor vacuum hose to the gas filter on the intake manifold
  5. Brake booster vacuum hose to the intake manifold
  6. A/C idle-up valve connector
  7. A/C idle-up valve hose to the intake manifold
  8. A/C idle-up valve hose to the air pipe
  9. DLC1 to the bracket
  10. Engine harness protector to the bracket
  11. Ground cable and the ground strap
  12. Heater hose to the water outlet and the heater hose to the water bypass pipe
  13. Fuel inlet hose to the fuel filter
  14. Fuel inlet hose with 2 new gaskets and the union bolt.
  15. Bolt: 22 ft. lbs. (30 Nm).
  16. Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister
  17. Power steering air hoses to the intake manifold and the air pipe.
  18. Radiator
  19. On models equipped with cruise control, install the actuator cable to the clamps.
  20. Accelerator cable to the throttle body, cable bracket, and the clamps.
  21. Air cleaner
  22. Battery tray and battery
  23. Hood
  24. Refill the transaxle assembly, engine oil and coolant.
  25. Negative battery cable
  26. Engine undercover
  • Start the vehicle, check for leaks and repair if necessary.

5S-FE Engines

  • Before servicing the vehicle, refer to the Precautions section.
  • Drain the cooling system.
  • Drain the engine oil.
  • Drain the transaxle fluid.
  • Remove or disconnect the following:

     

NOTE: On vehicles equipped with an air bag, wait at least 90 seconds before proceeding after disconnecting the negative battery cable.

  1. Negative battery cable.
  • Remove or disconnect the following:
  1. Battery and battery tray
  2. Hood
  3. Engine undercover
  4. Accelerator cable from the throttle body.
  5. With automatic transmission, throttle cable
  6. Air cleaner, resonator, and air intake hose
  7. On models with cruise control, actuator cover, actuator with the bracket.
  8. Ground strap at the battery carrier
  9. Radiator and coolant reservoir hose
  10. Washer tank, electrical lead and hose
  • To disconnect the wiring harness, tag and disconnect the following:
  1. The 5 connectors to the engine relay box
  2. The igniter connector
  3. The noise filter connector
  4. The connector at the left-hand fender apron
  5. The 2 ground straps from the left-hand and right-hand fender aprons
  6. The DLC1
  7. Disconnect the MAP sensor connector
  • Remove or disconnect the following:
  1. Dash panel undercover, glove compartment door, glove compartment, cowl harness connectors and the 2 ECM connectors
  2. Heater hoses, fuel return hose, and fuel inlet hose
  3. With manual transmission, starter and the clutch release cylinder.
  4. Don't disconnect the hydraulic line, simply hang the cylinder out of the way
  5. Transaxle control cables at the transaxle
  6. Tag and disconnect all remaining vacuum hoses and connectors
  7. Engine wire from the cowl panel
  8. A/C compressor, without disconnecting the refrigerant lines
  9. Front exhaust pipe bracket and the front pipe from the exhaust manifold
  10. Halfshafts
  11. Without disconnecting the hydraulic lines, power steering pump
  12. Left engine mounting insulator
  13. Right rear engine mounting insulator
  14. Front right engine mounting insulator
  • Attach an engine lifting device to the lift hooks. Remove the 3 bolts and disconnect the control rod. Slowly and carefully, lift the engine/transaxle assembly out of the engine compartment.
  • If equipped with automatic transmission, remove the starter. Separate the engine assembly from the transaxle.

To install:

  • Install or connect the following:
  1. Engine assembly to the transaxle
  2. With automatic transmission, starter
  3. Engine control rod.
  4. Bolts: 47 ft. lbs. (64 Nm).
  5. Front right engine mount.
  6. Bolts: 59 ft. lbs. (80 Nm).
  7. Rear engine mount.
  8. Nuts: 48 ft. lbs. (66 Nm).
  9. Left mount.
  10. Bolts (3 or 4): 47 ft. lbs. (64 Nm).
  11. Power steering pump.
  12. Bolts: 31 ft. lbs. (43 Nm).
  13. Install the drive belt and connect the 2 air hoses to the air pipe.
  14. Halfshafts
  15. Front pipe to the manifold.
  16. Nuts: 46 ft. lbs. (62 Nm).
  17. A/C compressor.
  18. Bolts: 20 ft. lbs. (27 Nm).
  • Feed the engine harness through the cowl and reattach the clamp to the cowl. Make the following connections:
  1. The 2 ECM connectors
  2. The 2 cowl wire connectors
  3. Install the glove compartment and door
  4. Install the lower instrument panel and the undercover
  • Install or connect the following:
  1. Vacuum hoses and the transaxle control cables
  2. On manual transmission vehicles, release cylinder and the starter
  3. Fuel inlet hose and tighten it to 22 ft. lbs. (29 Nm).
  4. Connect the return hose and the 2 heater hoses.
  5. Attach the 5 connectors to the relay box
  6. The connectors from the left-hand fender apron Install the engine relay box
  7. The igniter connector
  8. On California models, the ignition coil connector
  9. The noise filter connector
  10. The 2 ground straps from the left-hand and right-hand fender apron
  11. The DLC1
  12. The MAP sensor connector
  13. Washer tank and connect the electrical lead and hose
  14. Coolant reservoir hose and the radiator
  15. With cruise control, actuator and bracket.
  16. Connect the actuator connector and install the cover.
  17. Ground strap to the battery carrier.
  18. Air cleaner assembly
  19. On California models, air hose to the air cleaner assembly and connect the air intake temperature sensor connector
  20. With automatic transmission, throttle cable
  21. Accelerator cable
  22. Battery tray and battery
  23. Hood
  24. Oil and coolant
  25. Negative battery cable
  26. Undercover
  • Start the vehicle, check for leaks and repair if necessary.

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Toyota Corolla motor

Great Tips for Toyota Corolla motor engine replacement. It really helped me.

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