Toyota Celica, Corolla, ECHO & MR2 1999-05

Engine 2

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Removal & Installation





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Fig. Engine under covers should be removed to access all underneath components



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Fig. Only a few bolts retain the left engine cover

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.
 



Click image to see an enlarged view

Fig. Place a fender and seat covers on the car before working to spare exterior scratches and a soiled interior

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

  1. Disconnect the negative battery cable. Wait at least 90 seconds after the battery cable is disconnected to hinder air bag deployment.
  2.  


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.

  1. Remove the battery.
  2.  
  3. With the aid of an assistant, unbolt and remove the hood.
  4.  
  5. Raise and safely support the front of the vehicle securely on jackstands. Remove the engine undercovers.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Drain the engine oil from the crankcase.
  10.  
  11. Drain the transaxle case fluid.
  12.  
  13. 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.
  14.  
  15. Disconnect the accelerator cable from the throttle body and cable bracket.
  16.  
  17. Disconnect the cruise control actuator cable from its clamps.
  18.  
  19. On Canadian models, disconnect the relay box for the daytime running lights system from the radiator.
  20.  
  21. Remove the radiator. Be sure to label all wiring and hoses and pipes.
  22.  
  23. Disconnect the following wiring:
    1. Manifold Absolute Pressure (MAP) sensor vacuum hose from the gas filter on the intake manifold
    2.  
    3. Power steering air hose from the intake manifold
    4.  
    5. Power steering hose from the air pipe
    6.  
    7. Brake booster vacuum hose from the intake manifold
    8.  
    9. A/C idle-up valve connector
    10.  
    11. A/C idle-up valve hose from the intake manifold
    12.  
    13. A/C idle-up valve hose from the air pipe
    14.  
    15. Data Link Connector (DLC1) from the bracket
    16.  
    17. Engine wire protector with bracket
    18.  
    19. Ground cable and strap from body
    20.  
    21. 2 heater hoses from the water inlet housing
    22.  
    23. Fuel inlet hose from the fuel filter
    24.  
    25. Fuel return hose from return pipe
    26.  
    27. EVAP hose from charcoal canister
    28.  

  24.  
  25. Disconnect and labile the engine wire from the engine compartment relay box.
  26.  
  27. Remove the scuff plate, cowl side trim and lower instrument finish panel.
  28.  
  29. Disconnect the engine wire from the clamp of the ECM bracket, the ECM connections, circuit opening relay wiring and A/C amplifier connection.
  30.  



Click image to see an enlarged view

Fig. Be careful when removing the ECM

  1. Detach the MAP sensor wiring and separate from the bracket.
  2.  
  3. Unclamp the engine wire from the bracket.
  4.  
  5. Remove the nuts holding the engine wire retainer to the cowl panel.
  6.  
  7. Pull out the engine wire from the cabin.
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove both driveshafts.
  12.  
  13. Remove the alternator drive belt.
  14.  
  15. Separate, suspend and secure the A/C compressor from the engine but do NOT disconnect any lines.
  16.  
  17. Separate, suspend and secure the power steering pump from the engine but do NOT disconnect any lines.
  18.  
  19. On the 5S-FE engine, remove the starter motor assembly.
  20.  
  21. Remove the bolts, and disconnect the A/C relay box.
  22.  
  23. On manual transaxles, disconnect the clutch slave cylinder.
  24.  
  25. Disconnect the transaxle control cables.
  26.  
  27. On automatics, disconnect the transaxle control cable from the engine mounting center member.
  28.  
  29. Remove the exhaust pipe support bracket.
  30.  
  31. Remove the engine mounting center crossmember two dust covers from the rear.
    1. Disconnect the A/C pipe from the bracket.
    2.  
    3. Remove the bolt and nut holding the front engine mounting bracket to the mounting insulator.
    4.  
    5. Remove the bolt holding the rear engine mounting bracket to the mounting insulator.
    6.  
    7. Remove the bolt and the two nuts holding the rear engine mounting insulator to the front suspension crossmember.
    8.  
    9. Remove the bolts and the rear engine mounting bracket.
    10.  
    11. Remove the bolts holding the center member and rear engine mounting insulator.
    12.  

  32.  
  33. Attach the No. 1 engine hanger in the correct direction. Attach the engine chain hoist to the hanger.
  34.  



Click image to see an enlarged view

Fig. Install a No. 1 engine hanger in the correct direction


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

  1. Remove the two bolts and nut, then disconnect the LH engine mounting bracket from the insulator. Remove the through bolt and LH engine insulator.
  2.  



Click image to see an enlarged view

Fig. Lift the engine out of the vehicle slowly and carefully

  1. Disconnect the ground strap connector. Remove the bolt and nuts, then disconnect the RH engine bracket from the insulator.
  2.  

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

  1. Place the engine and transaxle assembly onto the stand.
  2.  
  3. Separate the engine from the transaxle.
  4.  
  5. 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:
    1. Secure the engine to the transaxle and tighten the retaining bolts to:

      12mm-17 ft. lbs. (23 Nm)
       
      14mm-34 ft. lbs. (46 Nm)
       
      17mm-47 ft. lbs. (64 Nm)
       

    2.  

  6.  
  7. 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.
  8.  
  9. Keep the engine level, and align the RH and LH mountings with the body mountings.
  10.  
  11. 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.
  12.  
  13. Attach the ground strap wiring, remove the engine chain hoist, bolt and engine No. 1 hanger.
  14.  
  15. 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).
  16.  
  17. 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.
  18.  
  19. Tighten the two bolts holding the center member to the body to 26 ft. lbs. (35 Nm).
  20.  
  21. Tighten the bolt and two nuts holding the rear engine mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm).
  22.  
  23. Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88Nm).
  24.  
  25. 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.
  26.  
  27. Install the battery.
  28.  
  29. Attach the battery cables.
  30.  
  31. 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.
  32.  


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

  1. Install the engine under covers and hood. Road test the vehicle and recheck the fluid levels.
  2.  

1NZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. Remove or disconnect the following:

    Hood
     
    Battery and tray
     
    Outer front cowl top panel
     
    Engine under covers
     
    Accelerator cable
     
    Air cleaner cap and related parts
     
    Air cleaner case and related parts
     
    All tubes, hoses and connectors attached to the engine
     
    Accessory drive belts
     
    Alternator
     
    Radiator
     
    With A/C, position the compressor out of the way
     
    With MT, the clutch release cylinder
     
    Transaxle control cables
     
    Fusible link
     
    Power steering pump
     
    Center exhaust pipe
     
    Halfshafts
     
    Suspension cross member
     
    Rear engine mount
     

  10.  
  11. Attach a shop crane to the engine hangers.
  12.  
  13. Remove all remaining engine mount bolts/nuts.
  14.  
  15. Remove the engine/transaxle assembly.
  16.  

To install:

  1. Install or connect the following:

    Engine/transaxle assembly into position
     
    Right engine mount insulator. Torque the bolts to 35 ft. lbs. (47 Nm).
     
    Left engine mount. Torque the bolts to 35 ft. lbs. (47 Nm).
     
    Rear engine mount bracket. Torque the bolts to 35 ft. lbs. (47 Nm).
     
    Rear engine mount insulator. Torque the bolt to 47 ft. lbs. (64 Nm).
     
    Suspension cross member. Torque the rear mount bolts to 86 ft. lbs. (116 Nm); the front mount bolts to 52 ft. lbs. (70 Nm).
     
    Halfshafts
     
    Center exhaust pipe
     
    Power steering pump
     
    Fusible link
     
    Transaxle control cables
     
    Clutch release cylinder. Torque the 2 bolts to 10 ft. lbs. (13 Nm).
     
    Compressor. Torque the 4 bolts to 18 ft. lbs. (25 Nm).
     
    Radiator
     
    Alternator
     
    All remaining tubes, hoses and connectors
     
    Air cleaner case
     
    Air cleaner cap
     
    Accelerator cable
     
    Outer front cowl top panel
     
    Engine under covers
     
    Battery and tray
     
    Coolant
     
    Engine oil
     
    Transaxle oil
     
    Hood
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

1ZZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Battery
     
    Hood
     
    Undercover
     
    Accelerator cable
     
    With automatic transmission, throttle cable from the accelerator cable.
     
    Radiator and cooling fan
     
    Air cleaner assembly
     
    Coolant reservoir tank stay
     
    Electrical connector, the hose, the mounting bolt, and remove the washer tank
     
    Cruise control actuator
     
    The Manifold Absolute Pressure (MAP) sensor vacuum hose from the gas filter on the intake manifold
     
    The brake booster vacuum hose from the intake manifold
     
    With air conditioning: the air conditioning vacuum hose from the actuator
     
    With power steering: the air hose from the air pipe
     
    With air conditioning: the air conditioning actuator connector
     

  12.  
  13. Disconnect the following wires and connectors from the right-hand fender apron as follows:
    1. The ground strap connector.
    2.  
    3. The MAP sensor connector.
    4.  
    5. With air conditioning: the air conditioning pressure switch.
    6.  
    7. The engine wiring harness from the fender apron.
    8.  

  14.  
  15. Remove or disconnect the following:

    Data Link Connector 1 (DLC1) connector and ground strap from the left-hand fender apron.
     
    Engine relay box and 4 connectors.
     
    Charcoal canister
     
    Heater hoses from water inlet housing
     
    Fuel inlet and return hoses
     
    With manual transmission, clutch release cylinder without disconnecting the pipe
     
    Transaxle control cable(s)
     

  16.  
  17. To disconnect the engine wiring harness, disconnect or remove the following components:

    Left-hand and right-hand front door scuff plate
     
    Lower finish panel
     
    Lower panel with the glove compartment
     
    Radio and center cluster finish panel
     
    Rear console box
     
    On manual transmission, shift lever knob
     
    On automatic transmission, shifting hole bezel
     
    Lower center finish panel
     
    Floor carpet bracket
     
    The 3 ECM connectors and cowl wire connector
     

  18.  
  19. Remove or disconnect the remaining components:

    Air conditioning compressor
     
    Front exhaust pipe
     
    Halfshafts
     
    Power steering pump
     
    Engine mounting center member
     
    Through-bolt and nut holding the mounting insulator to the mounting bracket
     
    Engine and transaxle assembly
     
    Front and rear engine mounting bracket
     
    Starter
     
    Separate the transaxle from the engine
     

  20.  

To install:

  1. Install or connect the following:

    Engine to the transaxle
     
    Starter
     
    Rear engine mounting bracket bolts: 57 ft. lbs. (77 Nm).
     
    Front engine mounting bracket. bolts: 57 ft. lbs. (77 Nm).
     
    Engine and transaxle assembly into the vehicle
     
    Engine mounting center member.
     
    Front engine mounting insulator through-bolt and nut. Torque the bolt to 64 ft. lbs. (87 Nm).
     
    Halfshafts
     
    Front exhaust pipe
     
    Power steering pump. Torque the bolts to 29 ft. lbs. (39 Nm).
     
    Drive belt
     
    Air conditioner compressor. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Drive belt and reconnect the connector.
     

  2.  
  3. To install and connect the engine wiring harness, perform the following:

    Push the wire through the cowl
     
    Connect the 3 ECM connectors
     
    Attach the cowl wire connector
     
    Floor carpet bracket
     
    Center lower finish panel
     
    With automatic transmission, install the shifting hole bezel, with manual transmission, install the shift lever knob
     
    Rear console box
     
    Center cluster finish panel and the radio
     
    Lower panel with the glove compartment door
     
    Right and left-hand door scuff plates
     
    Lower finish panel
     

  4.  
  5. Install or connect the following:

    With manual transmission, clutch release cylinder
     
    Transaxle control cable(s)
     
    Fuel return and inlet hose. Torque the bolt to 22 ft. lbs. (29 Nm).
     
    Heater hoses to the water inlet housing
     
    Charcoal canister
     

  6.  
  7. Connect the following wires and connectors on the left-hand fender apron:

    The 4 connectors to the engine relay box
     
    Engine relay box
     
    The DLC1 connector
     
    The connector on the fender apron
     
    The ground strap on the fender apron
     

  8.  
  9. Install or connect on the right-hand fender apron:

    The ground strap connector
     
    The MAP sensor connector
     
    With air conditioning, the air conditioning pressure switch
     
    The engine wire from the fender apron
     

  10.  
  11. Install or connect the following:

    With A/C, the actuator connector
     
    With power steering, the air hoses to the air pipe
     
    The vacuum hose from the MAP sensor to the gas filter to the intake chamber
     
    The brake booster vacuum hose to the air intake chamber
     
    With A/C, the vacuum hose from the actuator
     
    With cruise control, actuator, actuator cable and cover
     
    Electrical connector and vinyl hose
     
    Washer tank with the bolt
     
    Coolant reservoir tank stay
     
    Air cleaner
     
    Radiator and cooling fan
     
    With automatic transmission, connect the throttle cable.
     
    Accelerator cable
     
    All fluids
     
    Negative battery cable
     
    Undercovers and hood
     

  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Battery
     
    Hood
     
    Undercover
     
    Accelerator cable, cable bracket, and clamps.
     
    Air cleaner
     
    Cruise control actuator cable
     
    Radiator
     
    MAP sensor vacuum hose from the gas filter on the intake manifold
     
    Power steering air hose from the intake manifold
     
    Power steering hose from the air the air pipe
     
    Brake booster vacuum hose from the intake manifold
     
    Air conditioning idle-up valve
     
    Air conditioning idle-up valve hose from the intake manifold
     
    Air conditioning idle-up valve hose from the air pipe
     
    DLC1 from the bracket
     
    Engine wiring harness from the bracket
     
    Ground cable from the body and the ground strap from the body
     
    Heater hoses from the water outlet
     
    Heater hose from the water bypass pipe
     
    Fuel inlet hose from the fuel filter and the fuel return hose from the return pipe
     
    EVAP hose from the charcoal canister
     
    Engine wiring harness from the engine compartment relay box
     

  12.  
  13. To remove the engine wiring harness from the passenger-s compartment, remove or disconnect the following:

    The scuff plate
     
    The cowl side trim
     
    The finish panel from the lower instrument panel
     
    Front side of the floor carpet
     
    The wiring harness from the clamp of the ECM bracket
     
    The 3 ECM connectors
     
    The circuit opening relay connector
     
    The 3 connectors from the connectors on the bracket
     
    The A/C amplifier connector
     
    The MAP sensor connector
     
    The MAP sensor wire from the clamp on the bracket
     
    The wire clamp from the bracket
     
    The 2 nuts holding the engine wiring harness to the cowl
     

  14.  
  15. Remove or disconnect the following:

    Front exhaust pipe
     
    Halfshafts
     
    Alternator drive belt
     
    Air conditioning drive belt, compressor connector, and compressor. Do not disconnect the air conditioning lines
     
    Remove the drive belt and remove the 4 bolts that secure the power steering pump. Without disconnecting the lines, securely hang the pump out of the way
     
    A/C relay box
     
    On manual transmission, clutch release cylinder from the transaxle
     
    Transaxle control cable(s)
     
    On automatic transmission, transaxle control cable from the engine mounting center member.
     
    Exhaust pipe support bracket.
     

  16.  
  17. To remove the engine mounting center member, remove the following components:

    The 2 dust covers from the rear side of the member
     
    The A/C pipe from the bracket
     
    The bolt and nut holding the front engine mounting bracket to the mounting insulator
     
    The bolt holding the rear engine mounting bracket to the insulator
     
    The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member
     
    The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator
     

  18.  
  19. Remove or disconnect the remaining components:

    Attach an engine chain hoist to the engine hangers
     
    Left-hand engine mounting bracket from the mounting insulator
     
    Through-bolt and the left-hand mounting insulator
     
    Ground strap connector
     
    Right-hand engine mounting bracket from the mounting insulator
     
    Lift the engine and transaxle assembly from the vehicle
     
    Transaxle from the engine assembly
     

  20.  

To install:

  1. Install or connect the following:

    Transaxle to the engine assembly.
     
    Engine into the engine compartment
     
    Right-hand engine mounting bracket to the mounting insulator. Temporarily install the 3 nuts.
     
    Left-hand engine mounting insulator to the body with the through-bolt
     
    Left-hand engine mounting bracket to the mounting insulator and install the 2 bolts and nut. Bolts and nut: 47 ft. lbs. (64 Nm).
     
    Left-hand engine mounting through-bolt to the body. Bolt: 54 ft. lbs. (73 Nm).
     
    Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 Nm), 14mm nut: 38 ft. lbs. (52 Nm).
     
    Engine ground strap connector and remove the engine hoist.
     

  2.  
  3. To install the engine mounting center member, perform the following:

    Attach the center member together with the rear engine mounting insulator to the front suspension member
     
    Temporarily install the 2 bolts and nut holding the center member to the body
     
    Install the rear engine mounting bracket. Bolts: 58 ft. lbs. (78 Nm)
     
    Temporarily install the bolt and 2 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 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm)
     
    Tighten the bolt and 2 nuts holding the rear 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. (88 Nm)
     
    Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm
     
    Install the air conditioning pipe to the bracket and install the 2 dust covers to the center member
     

  4.  
  5. Install or connect the following:

    Exhaust pipe support bracket. Bolts to 14 ft. lbs. (19 Nm).
     
    Transaxle control cable(s)
     
    On automatic transmission, transaxle control cable to the engine mounting center member.
     
    On manual transmission, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt.
     
    A/C relay box to the body
     
    Power steering pump. 12mm bolts: 14 ft. lbs. (19 Nm). 14mm bolts: 29 ft. lbs. (39 Nm). Install the drive belt. Adjusting bolt: 29 ft. lbs. (39 Nm).
     
    A/C compressor. Bolts: 18 ft. lbs. (25 Nm).
     
    A/C drive belt with the adjusting bolt. Torque the locknut to 29 ft. lbs. (39 Nm). Connect the connector.
     
    Alternator drive belt
     
    Halfshafts
     
    Front exhaust pipe
     

  6.  
  7. To install the engine wiring harness in the passenger compartment, perform the following:

    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
     
    Connect the harness to the clamp on the ECM
     
    Connect the 3 ECM connectors and the circuit opening relay connector
     
    Connect the 3 connectors to the connectors on the bracket
     
    Connect the A/C amplifier connector
     
    Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff plate
     

  8.  
  9. Install or connect the following:

    Engine wiring harness with the 2 connectors to the engine compartment relay box and install the relay box covers
     
    MAP sensor connector
     
    MAP sensor wire to the clamp on the bracket
     
    MAP sensor vacuum hose to the gas filter on the intake manifold
     
    Brake booster vacuum hose to the intake manifold
     
    A/C idle-up valve connector
     
    A/C idle-up valve hose to the intake manifold
     
    A/C idle-up valve hose to the air pipe
     
    DLC1 to the bracket
     
    Engine harness protector to the bracket
     
    Ground cable and the ground strap
     
    Heater hose to the water outlet and the heater hose to the water bypass pipe
     
    Fuel inlet hose to the fuel filter
     
    Fuel inlet hose with 2 new gaskets and the union bolt. Bolt: 22 ft. lbs. (30 Nm).
     
    Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister
     
    Power steering air hoses to the intake manifold and the air pipe
     
    Radiator
     
    Actuator cable to the clamps, on models equipped with cruise control
     
    Accelerator cable to the throttle body, cable bracket, and the clamps
     
    Air cleaner
     
    Battery tray and battery
     
    Hood
     
    Negative battery cable
     
    Engine undercover
     

  10.  
  11. Refill the transaxle assembly, engine oil and coolant.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  



Click image to see an enlarged view

Fig. MR2 engine mounting exploded view

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the engine oil
  8.  
  9. Drain the transaxle fluid
  10.  
  11. Remove or disconnect the following:

    Engine hood
     
    Rear suspension upper brace
     
    Engine undercovers
     
    Battery and tray
     
    Air cleaner assembly and intake air hose
     
    Accelerator cable
     
    Rear bumper cover
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Front exhaust pipe
     
    Accessory drive belt
     
    A/C compressor
     
    Engine wiring harness connectors in the luggage compartment. Pull the harness through the firewall.
     
    Transaxle control ECU harness connector
     
    Engine wire at Junction Box No. 1
     
    Engine ground wires
     
    Wire brackets
     
    Heater hoses
     
    Radiator hoses
     
    Fuel line
     
    Clutch hose
     
    Shift cables
     
    Axle halfshafts
     

  12.  
  13. Support the drivetrain from below.

    Left and right motor mounts
     
    Front and rear motor mounts
     
    Rear subframe
     

  14.  
  15. Lower the drivetrain assembly from the vehicle.
  16.  
  17. Remove the starter.
  18.  
  19. Remove the transaxle flange bolts and separate the engine and transaxle.
  20.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Rear subframe. Tighten the bolts to 59 ft. lbs. (80 Nm).
     
    Front and rear motor mounts. Tighten the through bolts to 69 ft. lbs. (93 Nm).
     
    Left and right motor mounts. Tighten the mounting fasteners to 38 ft. lbs. (52 Nm) and the through bolts to 64 ft. lbs. (87 Nm).
     
    A/C compressor. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Front exhaust pipe. Tighten the bolts to 32 ft. lbs. (43 Nm) and the nut to 46 ft. lbs. (62 Nm).
     

  2.  

2ZZ-GE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
     
    Battery
     
    Hood
     
    Undercover
     
    Accelerator cable, cable bracket, and clamps.
     
    Air cleaner
     
    ECM box
     
    Cruise control actuator cable
     
    Radiator
     
    MAP sensor vacuum hose from the gas filter on the intake manifold
     
    Power steering air hose from the intake manifold
     
    Power steering hose from the air the air pipe
     
    Brake booster vacuum hose from the intake manifold
     
    A/C idle-up valve
     
    A/C idle-up valve hose from the intake manifold
     
    A/C idle-up valve hose from the air pipe
     
    DLC1 from the bracket
     
    Engine wiring harness from the bracket
     
    Ground cable from the body and the ground strap from the body
     
    Heater hoses from the water outlet
     
    Heater hose from the water bypass pipe
     
    Fuel inlet hose from the fuel filter and the fuel return hose from the return pipe
     
    EVAP hose from the charcoal canister
     
    Engine wiring harness from the engine compartment relay box
     

  12.  
  13. To remove the engine wiring harness from the passenger-s compartment, remove or disconnect the following:

    The scuff plate
     
    The cowl side trim
     
    The finish panel from the lower instrument panel
     
    Remove the front side of the floor carpet
     
    The wiring harness from the clamp of the ECM bracket
     
    The 3 ECM connectors
     
    The circuit opening relay connector
     
    The 3 connectors from the connectors on the bracket
     
    The A/C amplifier connector
     
    The MAP sensor connector
     
    The MAP sensor wire from the clamp on the bracket
     
    The wire clamp from the bracket
     
    The 2 nuts holding the engine wiring harness to the cowl
     

  14.  
  15. Remove or disconnect the following:

    Front exhaust pipe
     
    Exhaust manifold
     
    Halfshafts
     
    Alternator drive belt
     
    A/C drive belt, compressor connector, and compressor. Do not disconnect the A/C lines
     
    Remove the drive belt and remove the 4 bolts that secure the power steering pump. Without disconnecting the lines, securely hang the pump out of the way.
     
    A/C relay box
     
    On manual transmission, clutch release cylinder from the transaxle
     
    Transaxle control cable(s)
     
    On automatic transmission, transaxle control cable from the engine mounting center member.
     
    Exhaust pipe support bracket
     

  16.  
  17. To remove the engine mounting center member, remove the following components:

    The 2 dust covers from the rear side of the member
     
    The air conditioning pipe from the bracket
     
    The bolt and nut holding the front engine mounting bracket to the mounting insulator
     
    The bolt holding the rear engine mounting bracket to the insulator
     
    The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member
     
    The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator
     

  18.  
  19. Remove or disconnect the remaining components:

    Attach an engine chain hoist to the engine hangers
     
    Left-hand engine mounting bracket from the mounting insulator
     
    Through-bolt and the left-hand mounting insulator
     
    Ground strap connector
     
    Right-hand engine mounting bracket from the mounting insulator
     
    Lift the engine and transaxle assembly from the vehicle
     
    Transaxle from the engine assembly
     

  20.  

To install:

  1. Install or connect the following:

    Transaxle to the engine assembly
     
    Engine into the engine compartment
     
    Right-hand engine mounting bracket to the mounting insulator. Temporarily install the 3 nuts.
     
    Left-hand engine mounting insulator to the body with the through-bolt
     
    Left-hand engine mounting bracket to the mounting insulator and install the 2 bolts and nut. Bolts and nut: 47 ft. lbs. (64 Nm).
     
    Left-hand engine mounting through-bolt to the body. Bolt: 54 ft. lbs. (73 Nm).
     
    Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 Nm), 14mm nut: 38 ft. lbs. (52 Nm).
     
    Engine ground strap connector and remove the engine hoist
     

  2.  
  3. To install the engine mounting center member, perform the following:

    Attach the center member together with the rear engine mounting insulator to the front suspension member
     
    Temporarily install the 2 bolts and nut holding the center member to the body
     
    Install the rear engine mounting bracket. Bolts: 58 ft. lbs. (78 Nm)
     
    Temporarily install the bolt and 2 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 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm)
     
    Tighten the bolt and 2 nuts holding the rear 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. (88 Nm)
     
    Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm
     
    Install the A/C pipe to the bracket and install the 2 dust covers to the center member
     
    Exhaust manifold
     

  4.  
  5. Install or connect the following:

    Exhaust pipe support bracket. Bolts to 14 ft. lbs. (19 Nm).
     
    Transaxle control cable(s)
     
    On automatic transmission, transaxle control cable to the engine mounting center member.
     
    On manual transmission, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt
     
    A/C relay box to the body
     
    Power steering pump. 12mm bolts: 14 ft. lbs. (19 Nm). 14mm bolts: 29 ft. lbs. (39 Nm). Install the drive belt. Adjusting bolt: 29 ft. lbs. (39 Nm).
     
    A/C compressor. Bolts: 18 ft. lbs. (25 Nm).
     
    A/C drive belt with the adjusting bolt and tighten the idler pulley locknut to 29 ft. lbs. (39 Nm). Connect the connector.
     
    Alternator drive belt
     
    Halfshafts
     
    Front exhaust pipe
     

  6.  
  7. To install the engine wiring harness in the passenger compartment, perform the following:

    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
     
    Connect the harness to the clamp on the ECM
     
    Connect the 3 ECM connectors and the circuit opening relay connector
     
    Connect the 3 connectors to the connectors on the bracket
     
    A/C amplifier connector
     
    Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff plate
     

  8.  
  9. Install or connect the following:

    Engine wiring harness with the 2 connectors to the engine compartment relay box and install the relay box covers.
     
    MAP sensor connector
     
    MAP sensor wire to the clamp on the bracket
     
    MAP sensor vacuum hose to the gas filter on the intake manifold
     
    Brake booster vacuum hose to the intake manifold
     
    A/C idle-up valve connector
     
    A/C idle-up valve hose to the intake manifold
     
    A/C idle-up valve hose to the air pipe
     
    DLC1 to the bracket
     
    Engine harness protector to the bracket
     
    Ground cable and the ground strap
     
    Heater hose to the water outlet and the heater hose to the water bypass pipe
     
    Fuel inlet hose to the fuel filter
     
    Fuel inlet hose with 2 new gaskets and the union bolt. Bolt: 22 ft. lbs. (30 Nm).
     
    Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister
     
    Power steering air hoses to the intake manifold and the air pipe.
     
    Radiator
     
    On models equipped with cruise control, install the actuator cable to the clamps.
     
    Accelerator cable to the throttle body, cable bracket, and the clamps.
     
    Air cleaner
     
    Battery tray and battery
     
    Hood
     
    Refill the transaxle assembly, engine oil and coolant.
     
    Negative battery cable
     
    Engine undercover
     

  10.  
  11. Start the vehicle, check for leaks and repair if necessary.
  12.  

5S-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. 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.



    Negative battery cable.
     

  10.  
  11. Remove or disconnect the following:

    Battery and battery tray
     
    Hood
     
    Engine undercover
     
    Accelerator cable from the throttle body. With automatic transmission, throttle cable
     
    Air cleaner, resonator, and air intake hose
     
    On models with cruise control, actuator cover, actuator with the bracket.
     
    Ground strap at the battery carrier
     
    Radiator and coolant reservoir hose
     
    Washer tank, electrical lead and hose
     

  12.  
  13. To disconnect the wiring harness, tag and disconnect the following:

    The 5 connectors to the engine relay box
     
    The igniter connector
     
    The noise filter connector
     
    The connector at the left-hand fender apron
     
    The 2 ground straps from the left-hand and right-hand fender aprons
     
    The DLC1
     
    Disconnect the MAP sensor connector
     

  14.  
  15. Remove or disconnect the following:

    Dash panel undercover, glove compartment door, glove compartment, cowl harness connectors and the 2 ECM connectors
     
    Heater hoses, fuel return hose, and fuel inlet hose
     
    With manual transmission, starter and the clutch release cylinder. Don't disconnect the hydraulic line, simply hang the cylinder out of the way
     
    Transaxle control cables at the transaxle
     
    Tag and disconnect all remaining vacuum hoses and connectors
     
    Engine wire from the cowl panel
     
    A/C compressor, without disconnecting the refrigerant lines
     
    Front exhaust pipe bracket and the front pipe from the exhaust manifold
     
    Halfshafts
     
    Without disconnecting the hydraulic lines, power steering pump
     
    Left engine mounting insulator
     
    Right rear engine mounting insulator
     
    Front right engine mounting insulator

    Click image to see an enlarged view

    Fig. Use a hoist to remove the engine assembly

     

  16.  
  17. 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.
  18.  
  19. If equipped with automatic transmission, remove the starter. Separate the engine assembly from the transaxle.
  20.  

To install:

  1. Install or connect the following:

    Engine assembly to the transaxle
     
    With automatic transmission, starter
     
    Engine control rod. Bolts: 47 ft. lbs. (64 Nm).
     
    Front right engine mount. Bolts: 59 ft. lbs. (80 Nm).
     
    Rear engine mount. Nuts: 48 ft. lbs. (66 Nm).
     
    Left mount. Bolts (3 or 4): 47 ft. lbs. (64 Nm).
     
    Power steering pump. Bolts: 31 ft. lbs. (43 Nm). Install the drive belt and connect the 2 air hoses to the air pipe.
     
    Halfshafts
     
    Front pipe to the manifold. Nuts: 46 ft. lbs. (62 Nm).
     
    A/C compressor. Bolts: 20 ft. lbs. (27 Nm).
     

  2.  
  3. Feed the engine harness through the cowl and reattach the clamp to the cowl. Make the following connections:

    The 2 ECM connectors
     
    The 2 cowl wire connectors
     
    Install the glove compartment and door
     
    Install the lower instrument panel and the undercover
     

  4.  
  5. Install or connect the following:

    Vacuum hoses and the transaxle control cables
     
    On manual transmission vehicles, release cylinder and the starter
     
    Fuel inlet hose and tighten it to 22 ft. lbs. (29 Nm). Connect the return hose and the 2 heater hoses.
     
    Attach the 5 connectors to the relay box
     
    The connectors from the left-hand fender apron
     
    Install the engine relay box
     
    The igniter connector
     
    On California models, the ignition coil connector
     
    The noise filter connector
     
    The 2 ground straps from the left-hand and right-hand fender apron
     
    The DLC1
     
    The MAP sensor connector
     
    Washer tank and connect the electrical lead and hose
     
    Coolant reservoir hose and the radiator
     
    With cruise control, actuator and bracket. Connect the actuator connector and install the cover.
     
    Ground strap to the battery carrier.
     
    Air cleaner assembly
     
    On California models, air hose to the air cleaner assembly and connect the air intake temperature sensor connector
     
    With automatic transmission, throttle cable
     
    Accelerator cable
     
    Battery tray and battery
     
    Hood
     
    Oil and coolant
     
    Negative battery cable
     
    Undercover
     

  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

 
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