partial engine assembly3.pdf

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14–27
ENGINE MECHANICAL
–
PARTIAL ENGINE ASSY (April, 2003)
141GS–01
REPLACEMENT
1.
WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11–1 )
2.
REMOVE FRONT WHEELS
3.
REMOVE ENGINE UNDER COVER RH
4.
REMOVE ENGINE UNDER COVER LH
5.
DRAIN COOLANT (See page 16–7 )
6.
REMOVE CYLINDER HEAD COVER NO.2
(a)
Remove the 2 nuts, 2 clips and cylinder head cover.
A65077
7.
DISCONNECT RADIATOR HOSE INLET
(a)
Disconnect the radiator hose inlet from the radiator.
8.
DISCONNECT RADIATOR HOSE OUTLET
(a)
Disconnect the radiator hose outlet from the radiator.
9.
DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a)
Disconnect the oil cooler inlet tube from the radiator.
10.
DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a)
Disconnect the oil cooler outlet tube from the radiator.
11.
REMOVE RADIATOR SUPPORT UPPER (W/ AIR CONDITIONING)
(a)
Remove the 2 bolts and 2 radiator support upper.
12.
REMOVE RADIATOR ASSY (W/ AIR CONDITIONING)
(a)
Disconnect the connector and harness clamp, and remove the radiator.
13.
REMOVE BATTERY
14.
REMOVE BATTERY CARRIER
(a)
Remove the 4 bolts and battery carrier.
15.
REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a)
Disconnect the mass air flow sensor connector.
(b)
Disconnect the VSV connector.
C80159
2004 COROLLA (RM1037U)
Author:
Date:
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ENGINE MECHANICAL
–
PARTIAL ENGINE ASSY (April, 2003)
(c)
Disconnect the 3 vacuum hoses, as shown in the illustra-
tion.
(d)
Loosen the air cleaner hose clamp and disconnect the air
cleaner hose.
(e)
Remove the air cleaner cap.
(f)
Remove the air cleaner filter element.
A65177
(g)
Disconnect the wire harness clamp, connector and hose.
(h)
Remove the 3 bolts and air cleaner case.
A66032
16.
REMOVE EFI FUEL PIPE CLAMP (See page 11–10 )
17.
DISCONNECT FUEL TUBE SUB–ASSY (See page 11–10 )
18.
SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a)
Loosen the nut, then remove the accelerator control cable.
19.
SEPARATE CRUISE CONTROL ACTUATOR ASSY (W/
CRUISE CONTROL)
(a)
Disconnect the actuator connector.
(b)
Remove the 2 bolts, then separate the actuator from the
body.
A65807
20.
DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a)
Disconnect the union to connector tube hose from the brake booster.
21.
DISCONNECT HEATER INLET WATER HOSE
(a)
Disconnect the heater inlet water hose from the air condi-
tioner tube.
A65832
2004 COROLLA (RM1037U)
Author:
Date:
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ENGINE MECHANICAL
–
PARTIAL ENGINE ASSY (April, 2003)
22.
DISCONNECT HEATER OUTLET WATER HOSE
(a)
Disconnect the heater outlet water hose from the air con-
ditioner tube.
A65833
23.
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)
(See page 41–17 )
24.
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
(See page 41–17 )
25.
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
(See page 40–9 )
26.
SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41–17 )
27.
REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71–10 )
28.
DISCONNECT ENGINE WIRE
(a)
Disconnect the engine wire from the ECM and junction
block.
(b)
Pull out the engine wire.
(c)
Remove the engine room relay block cover.
(d)
Disconnect the engine wire from the engine room relay
block.
A66034
29.
REMOVE FAN AND GENERATOR V BELT
(a)
Slowly turn the V–ribbed belt tensioner clockwise, then
remove the V belt.
A60622
30.
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(See page 55–34 )
HINT:
Hang up the hoses instead of detaching.
2004 COROLLA (RM1037U)
Author:
Date:
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ENGINE MECHANICAL
–
PARTIAL ENGINE ASSY (April, 2003)
31.
SEPARATE RETURN TUBE SUB–ASSY
(a)
Separate the vane pump oil reservoir from the oil reser-
voir bracket.
(b)
Remove the 2 bolts installing the return tube.
A65809
32.
REMOVE FRONT DOOR SCUFF PLATE RH (See page 76–21 )
33.
REMOVE COWL SIDE TRIM BOARD RH (See page 71–10 )
34.
REMOVE COLUMN HOLE COVER SILENCER SHEET
(a)
Remove the 2 clips and column hole cover silencer sheet.
35.
SEPARATE STEERING INTERMEDIATE SHAFT (See page 51–18 )
36.
REMOVE FLOOR PANEL BRACE FRONT
(a)
Remove the 2 nuts and floor panel brace front.
37.
REMOVE EXHAUST PIPE ASSY FRONT (See page 15–2 )
38.
REMOVE FRONT AXLE HUB LH NUT (See page 30–6 )
SST
09930–00010
39.
REMOVE FRONT AXLE HUB RH NUT (See page 30–6 )
SST
09930–00010
40.
SEPARATE TIE ROD END SUB–ASSY LH (See page 30–6 )
SST
09628–62011
41.
SEPARATE TIE ROD END SUB–ASSY RH (See page 30–6 )
SST
09628–62011
42.
SEPARATE FRONT STABILIZER LINK ASSY LH (See page 51–18 )
43.
SEPARATE FRONT STABILIZER LINK ASSY RH (See page 51–18 )
44.
SEPARATE FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH (See page 30–6 )
45.
SEPARATE FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 RH (See page 30–6 )
46.
SEPARATE FRONT AXLE ASSY LH (See page 30–6 )
47.
SEPARATE FRONT AXLE ASSY RH (See page 30–6 )
48.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a)
Set the engine lifter.
(b)
Remove the 4 bolts, 2 nuts and engine mounting insula-
tor.
A64005
2004 COROLLA (RM1037U)
Author:
Date:
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ENGINE MECHANICAL
–
PARTIAL ENGINE ASSY (April, 2003)
(c)
Remove the through bolt and nut, then detach the engine
mounting insulator from the vehicle.
A55685
(d)
Remove the 6 bolts, as shown in the illustration.
(e)
Carefully, remove the engine with transaxle from the ve-
hicle.
A50289
(f)
Install the 2 engine hangers with the 2 bolts.
Part No.:
12281–15040 for No. 1 engine hanger
12281–22021 for No. 2 engine hanger
91512–B1016 for bolt
Torque: 38 N
Front Side:
Rear Side:
V
m (387 kgf
V
cm, 28 ft
V
lbf)
HINT:
Be sure to install the engine hanger (12281–22021) to the front
side of the engine and the engine hanger (12281–15040) to the
rear side.
(g) Using the chain block and engine sling device, hang the
engine assembly.
49. SEPARATE VANE PUMP ASSY (See page 51–8 )
NOTICE:
Do not disconnect the hose.
A62830
50.
REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a)
Remove the through bolt and nut, then detach the engine
mounting insulator FR from the engine mounting bracket.
A62711
2004 COROLLA (RM1037U)
Author:
Date:
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