Yaris 2007

Engine

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Removal & Installation



  1. Properly relieve the fuel system pressure.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the front wheels.
  6.  
  7. Remove the engine undercover.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Remove the wiper motor and regulator assembly.
  12.  
  13. Remove the air cleaner assembly.
  14.  
  15. Disconnect the radiator hoses.
  16.  
  17. Disconnect the transaxle oil cooler hoses.
  18.  
  19. Remove the engine cover.
  20.  
  21. Separate transmission control cable assembly.
  22.  
  23. Disconnect the union to check valve hose from the booster vacuum tube.
  24.  
  25. Disconnect the inlet and outlet heater hoses.
  26.  
  27. Disconnect fuel tube sub-assembly.
  28.  
  29. Remove the engine fan, alternator and accessory drive belt.
  30.  
  31. Separate clutch release cylinder assembly.
  32.  
  33. Disconnect engine wire:
    1. Pull up the lever and disconnect the connector of the engine control computer.
    2.  
    3. Remove the 2 connectors and the clamp from the engine room junction block and disconnect the wire harness.
    4.  
    5. Remove the bolt and separate the earth wire of the engine room wire harness.
    6.  
    7. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.
    8.  

  34.  
  35. Remove column hole cover silencer sheet.
  36.  
  37. Separate steering sliding yoke sub-assembly.
  38.  
  39. Remove steering column hole cover sub-assembly no. 1.
  40.  
  41. Remove instrument panel finish panel lower center (for sedan).
  42.  
  43. Remove instrument panel finish panel end LH (for sedan) .
  44.  
  45. Remove shift lever knob sub-assembly (for manual transaxle).
  46.  
  47. Remove shifting hole cover sub-assembly (for manual transaxle) .
  48.  
  49. Remove upper console panel sub-assembly (for sedan).
  50.  
  51. Remove console box cover rear (for hatchback) .
  52.  
  53. Remove console upper rear panel sub-assembly (for sedan).
  54.  
  55. Remove console box carpet (for sedan).
  56.  
  57. Remove rear console box assembly.
  58.  
  59. Remove instrument pad lower LH (for sedan).
  60.  
  61. Remove heated oxygen sensor.
  62.  
  63. Remove exhaust pipe assembly front.
  64.  
  65. Remove front axle shaft LH nut.
  66.  
  67. Remove front axle shaft RH nut.
  68.  
  69. Separate speed sensor front LH and RH (w/ABS).
  70.  
  71. Separate tie rod end sub-assembly LH and RH.
  72.  
  73. Separate front stabilizer link assembly LH and RH.
  74.  
  75. Separate front suspension arm sub-assembly lower no. 1 LH and RH.
  76.  
  77. Separate front axle assembly LH and RH.
  78.  
  79. Remove halfshaft assembly.
  80.  
  81. Remove flywheel housing under cover (for automatic transaxle).
  82.  
  83. Remove drive plate and torque converter clutch setting bolt (for automatic transaxle).
  84.  
  85. Remove engine assembly with transaxle:
    1. Set the engine lifter.
    2.  
    3. Remove the 5 bolts and the nut and remove the engine mounting insulator RH.

      Click image to see an enlarged view

      Fig. Remove the 5 bolts and the nut and remove the engine mounting insulator RH

    4.  

  86.  
  87. Remove the through bolt and the nut and separate the engine mounting insulator LH.

    Click image to see an enlarged view

    Fig. Remove the through bolt and the nut and separate the engine mounting insulator LH

  88.  
  89. Remove the 6 bolts, and remove the engine assembly with transaxle and the front suspension crossmember from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the 6 bolts, and remove the engine assembly with transaxle and the front suspension crossmember

  90.  

To install:

  1. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
  2.  
  3. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.
  4.  
  5. Install the engine mounting insulator LH with the through bolt and nut. Tighten to 38 ft. lbs. (52 Nm).
  6.  
  7. Install the engine mounting insulator RH with the 5 bolts and nut:
    1. Bolt A: 33 ft. lbs. (45 Nm).
    2.  
    3. Bolt B: 38 ft. lbs. (53 Nm).
    4.  
    5. Bolt C: 38 ft. lbs. (53 Nm).

      Click image to see an enlarged view

      Fig. Identifying RH engine mount insulator bolts and nut

    6.  

  8.  
  9. Operate the engine lifter and provisionally install the front suspension crossmember onto the vehicle with the 6 bolts.
  10.  
  11. Insert SST into the datum holes in the front suspension crossmembers RH and LH alternately and tighten bolts A, B and C on both sides in several sequences.
    1. Bolt A: 52 ft. lbs. (70 Nm).
    2.  
    3. Bolt B: 118 ft. lbs. (160 Nm).
    4.  
    5. Bolt C: 70 ft. lbs. (95 Nm).
      CAUTION
      Insert SST into the datum hole vertically. If impossible to insert SST vertically, loosen all the bolts and then insert SST again.



      Click image to see an enlarged view

      Fig. Identifying the front suspension crossmember bolts and SST 09670-00010

    6.  

  12.  
  13. Install drive plate and torque converter clutch setting bolt (for Automatic Transaxle). Tighten the 6 torque converter set bolts. Tighten to 20 ft. lbs. (27 Nm).
  14.  
  15. To complete the installation, reverse the remaining removal procedure.
  16.  
  17. Add engine coolant.
  18.  
  19. Add and inspect the transaxle fluid.
  20.  
  21. Inspect fan & generator V belt.
  22.  
  23. Check for fuel leakage.
  24.  
  25. Check for engine oil leakage.
  26.  
  27. Check for exhaust gas leakage.
  28.  
  29. Check for engine coolant leakage.
  30.  
  31. Inspect ignition timing.
  32.  
  33. Inspect engine idling speed.
  34.  
  35. Inspect CO/HC:
    1. Start the engine.
    2.  
    3. Run the engine at 2,500 rpm for approximately 180 seconds.
    4.  
    5. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe while idling.
    6.  
    7. Check the CO/HC concentration during idling and when running at 2,500 rpm.
      NOTE
      When doing the 2 mode (with the engine idling/running at 2,500 rpm) test, the measuring procedures are determined by applicable local regulations.

    8.  
    9. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
    10.  
    11. Check the heated oxygen sensor operation.
    12.  
    13. See the table below for possible causes, then inspect the applicable parts and repair them if necessary.

      Click image to see an enlarged view

      Fig. Engine possible causes table

    14.  

  36.  
  37. Inspect front wheel alignment.
  38.  
  39. Inspect abs sensor signal (w/ ABS).
  40.  

 
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