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Home >> Toyota >> 2003 >> Matrix XRS 2WD L4-1.8L (2ZZ-GE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Partial Engine Assembly Replacement >> Part 1

Part 1

REPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. DRAIN COOLANT
6. DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
7. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
a. Using a 10 mm hexagon wrench, remove the drain plug and a gasket. Drain automatic transaxle fluid.
b. Install a new gasket and the drain plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
8. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 3 bolts, the nut and the cylinder head cover No. 2.
9. REMOVE BATTERY
10. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
a. Disconnect the MAF meter connector.
b. Place match marks on the vacuum hoses.





c. Disconnect the 5 vacuum hoses from the air cleaner cap.
d. Disconnect the 2 clamps, and connect the air cleaner cap from the air cleaner case.
e. Loosen the hose clamp bolt, and disconnect the air cleaner hose from the throttle body.
f. Remove the air cleaner assembly with hose.
g. Remove the air filter.





h. Disconnect the wire harness clamp, connector and hose.
i. Remove the 3 bolts and the air cleaner case.





11. REMOVE BATTERY CARRIER
a. Remove the 4 bolts and battery carrier.





12. SEPARATE ACCELERATOR CONTROL CABLE ASSY





13. REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
a. Disconnect the actuator connector.
b. Remove the 2 bolts, and disconnect the actuator from the body.





14. REMOVE WIRE HARNESS CLAMP
a. Disconnect engine wire harness.
b. Remove the bolt and wiring harness clamp bracket.





15. DISCONNECT SUCTION HOSE SUB-ASSY
a. Remove the 2 nuts installing the suction hose sub-assy.
b. Disconnect the suction hose sub-assy.





16. REMOVE FAN AND GENERATOR V-BELT
a. Turn the drive belt tensioner slowly clockwise and loosen it. Then, remove the drive belt and put back the drive belt tensioner little by little and fix it quietly.
17. REMOVE EFI FUEL PIPE CLAMP
18. DISCONNECT FUEL TUBE SUB-ASSY
19. DISCONNECT RADIATOR HOSE INLET
a. Disconnect the radiator hose inlet from the radiator.
20. DISCONNECT RADIATOR HOSE OUTLET
a. Disconnect the radiator hose outlet from the radiator.
21. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
22. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)
23. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)





24. DISCONNECT HEATER INLET WATER HOSE
a. Disconnect the heater inlet water hose from the air conditioner tube.





25. DISCONNECT HEATER OUTLET WATER HOSE
a. Disconnect the heater outlet water hose from the air conditioner tube.





26. DISCONNECT UNION TO CONNECTOR TUBE HOSE
a. Disconnect the union to check valve hose from the brake booster.
27. REMOVE GLOVE COMPARTMENT DOOR ASSY
28. DISCONNECT ENGINE WIRE





a. Remove the engine room relay block cover.
b. Disconnect the 3 connectors.





c. Disconnect the 2 wire harness clamps.





d. Disconnect the 2 ground cables from the vehicle.
e. Disconnect the 2 ECM connectors.
f. Disconnect the 3 cowl wire connectors from connectors on bracket.
g. Pull out the engine wire from the cabin.
29. REMOVE RADIATOR ASSY (W/ AIR CONDITIONER)
30. DISCONNECT CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
31. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)

HINT: Hung up the hoses instead of detaching.





32. SEPARATE RETURN TUBE SUB-ASSY
a. Remove the 2 clamp bolts, and separate the return tube sub-assy.
33. SEPARATE VANE PUMP OIL RESERVOIR ASSY
a. Remove the 2 bolts and the oil reservoir assy.
34. REMOVE FLOOR PANEL BRACE FRONT
35. REMOVE EXHAUST PIPE ASSY FRONT
36. REMOVE STEERING INTERMEDIATE SHAFT
37. REMOVE FRONT AXLE HUB LH NUT
SST 09930-00010
38. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010

HINT: Perform the same procedure on the opposite side.

39. SEPARATE TIE ROD END SUB-ASSY LH
SST 09628-62011
40. SEPARATE TIE ROD END SUB-ASSY RH
SST 09628-62011

HINT: Perform the same procedure on the opposite side.

41. SEPARATE FRONT STABILIZER LINK ASSY LH
42. SEPARATE FRONT STABILIZER LINK ASSY RH

HINT: Perform the same procedure on the opposite side.

43. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
44. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH

HINT: Perform the same procedure on the opposite side.

45. SEPARATE FRONT AXLE ASSY LH)
46. SEPARATE FRONT AXLE ASSY RH

HINT: Perform the same procedure on the opposite side.

47. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE





a. Set the engine lifter.
b. Remove the 5 bolts, 2 nuts and engine mounting insulator RH.





c. Remove the through bolt and nut, detach the engine mounting insulator LH from the vehicle.





d. Remove the 6 bolts, as shown in the illustration.
e. Carefully, remove the engine assembly from the vehicle.





f. Install the 2 engine hangers as shown in the illustration.
Parts No.:
No. 1 engine hanger 12281-88600
No. 2 engine hanger 12282-88600
Bolt: 91512-61020
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)

HINT: Be sure to install engine hanger (12281-88600) to the front side of the engine, and engine hanger (12282-88600) to the rear side.

g. Using the chain block and engine sling device, hang the engine assembly.
48. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER





a. Remove the through bolt and a nut, detach the engine mounting insulator FR from the engine mounting bracket.





b. Remove the through bolt, detach the engine mounting insulator RR from the suspension crossmember.
c. Separate the engine and transaxle assembly from the front suspension crossmember w/center member.
49. REMOVE STARTER ASSY
50. REMOVE FRONT DRIVE SHAFT ASSY RH
SST 09520-01010, 09520-24010 (09520-32040)
51. SEPARATE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
52. SEPARATE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
53. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE)
54. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE)





55. REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL
a. Fix the crankshaft with SST, then remove the drive plate and ring gear or the flywheel.
SST 09213-70011 (09213-70020), 09330-00021
56. INSTALL ENGINE STAND
57. REMOVE OIL LEVEL GAGE SUB-ASSY
58. REMOVE OIL LEVEL GAGE GUIDE





59. REMOVE SURGE TANK STAY NO.1
a. Remove the 2 bolts, the nut and the surge tank stay.





60. REMOVE INTAKE MANIFOLD
a. Remove the 4 bolts, the 2 nuts, the intake manifold and the gasket.
61. REMOVE V-RIBBED BELT TENSIONER ASSY
a. Remove the bolt, the nut and the v-ribbed belt tensioner assy.





62. REMOVE MANIFOLD STAY
a. Remove the 2 bolts, the nut and exhaust manifold stay.
63. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
64. REMOVE EXHAUST MANIFOLD
a. Remove the 3 bolts, 2 nuts, exhaust manifold and gasket.
65. REMOVE GENERATOR BRACKET NO.1
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