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Engine & Engine Overh . . .

Engine & Engine
Overhaul:

Engine Mechanical

Engine

Rocker Arm (Valve)
Cover

Thermostat

Intake Manifold

Exhaust Manifold

Radiator

Electric Cooling Fan

Water Pump

Cylinder Head

Oil Pan

Oil Pump

Timing Belt Cover

Timing Belt and
Sprockets

Camshaft and Bearings

Engine Core Plugs
(Freeze Plugs)

Rear Main Seal

Flywheel and Ring Gear

Exhaust System

Engine Reconditioning

Specifications Charts

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Intake Manifold

Engine

Toyota Corolla 1988-1997 Repair Guide

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 guide.

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.

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ENGINE STAND

OIL FILTER

Learn More About It:

ANTIFREEZE NEEDED

OIL(CRANKCASE)CAPACITY

OIL (CRANKCASE) TYPE

AND WEIGHT

EXHAUST BOLT TORQUE

Loan-a-Tool:

Engine Lift Chain

Torque Wrench

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 in this guide.

4A-F Engine

Disconnect the negative battery cable.

Remove the battery.

Remove the hood (mark the hood hinges for correct installation). Have
a helper assist you and be careful not to damage the painted bodywork.

Remove the engine under covers.

Drain the cooling system, engine and transaxle fluids.

Removwe the air cleaner and flexible hose.

Remove the coolant reservoir tank, radiator and fan.

If equipped with an automatic, disconnect the accelerator and throttle
cables at the carburetor.

Lable and disconnect all electrical wiring and vacuum lines necessary to
remove the engine.

Disconnect the fuel lines at the fuel pump. Plug the lines.

10.

Disconnect the heater hoses at the water inlet housing.

11.

Remove the power steering pump and set aside with the lines still
attached.

12.

Remove the air conditioning compressor and set it aside with the
refrigerant lines still attached.

13.

Disconnect the speedometer cable from the transaxle.

14.

On manual transaxles, remove the slave cylinder and set aside with the
hydraulic lines still attached.

15.

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Disconnect the shift control cables.

16.

Raise and support the vehicle.

17.

Remove the 2 nuts from the flange then, disconnect the exhaust pipe
from the exhaust manifold.

18.

Disconnect the halfshafts at the transaxle.

19.

Remove the 2 hole covers, then remove the front, center and rear
engine mounts from the center crossmember. Remove the bolts,
insulators and center member.

20.

Attach a suitable hoisting device to the lifting brackets on the engine.

21.

Remove the bolts and mounting stay. Remove the bolt, nuts and the
through-bolt. Next pull out the right side engine mount. Remove the
bolts retaining the left mounting stay. Unbolt and remove the left
engine mount bracket from the transaxle.

22.

Inspect and make sure all components are disconnected and labeled.
Lift the engine/transaxle assembly out of the vehicle.

23.

To install:

Install the engine in the reverse order of removal paying particular
attention to the following.

24.

Before reinstalling the engine in the car, several components must be
reattached or connected. Install the transaxle to the engine (if
separated); tighten the 12mm bolts to 47 ft. lbs. (64 Nm) and the
10mm bolts to 34 ft. lbs. (46 Nm). Tighten all other components to the
following specifications:

Starter mounting bolts-29 ft. lbs. (39 Nm)

Right motor mount and through bolt-58 ft. lbs. (78 Nm).

Engine mounting automatics-38 ft. lbs. (52 Nm)

Engine mounting bracket-to-transaxle-45 ft. lbs. (61 Nm)

Engine mounting stay LH-15 ft. lbs. (21 Nm)

Engine mounting LH-to-transaxle manual-38 ft. lbs. (52 Nm)

Engine mounting stay RH-31 ft. lbs. (42 Nm)

Engine mounting RH-to-engine manual-nut-38 ft. lbs. (52 Nm)

Engine mounting RH-to-engine manual bolt-47 ft. lbs. (64 Nm)

Engine mounting bolt front-35 ft. lbs. (48 Nm)

Engine mounting bolt center-38 ft. lbs. (52 Nm)

Engine mounting bolt rear-42 ft. lbs. (57 Nm)

Engine front and rear mounting bolts-58 ft. lbs. (78 Nm)

Power steering pump pulley bolt-28 ft. lbs. (38 Nm)

Exhaust pipe-to-manifold-46 ft. lbs. (62 Nm)

25.

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Fill the transaxle with the correct amount of oil, and fill the engine with
oil.

26.

Fill the cooling system with the proper amount of fluid.

27.

Double check all installation items, paying particular attention to loose
hoses or hanging wires, untightened nuts, poor routing of hoses and
wires (too tight or rubbing) and tools left in the engine area.

28.

Connect the negative battery cable.

29.

Start the engine and allow it to reach normal operating temperature.
Check carefully for leaks. Shut the engine OFF.

30.

Raise the front end of the car, support on jackstands and install the
splash shields below the car.

31.

Lower the car to the ground. With your helper, install the hood and
adjust it for proper fit and latching. Road test the vehicle for proper
operation.

32.

4A-FE and 7A-FE Engines

See Figures 1 through 18

Remove the hood (mark the hood hinges for correct installation). Have
a helper assist you and be careful not to damage the painted bodywork.

Fig. 1: Exploded view of the engine removal components-4A-FE and 7A-FE engines

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Fig. 2: Exploded view of the engine removal components (continued)-4A-FE and 7A-FE engines

The fuel system is under pressure. Release pressure slowly and contain
spillage. Observe no smoking/no open flame precautions. Have a Class B-C
(dry powder) fire extinguisher within arm's reach at all times.

CAUTION

On models with an airbag, wait at least
90 seconds from the time that the
ignition switch is turned to the LOCK
position and the battery is disconnected
before performing any further work.
Refer to Chapter 7 for all air bag
warnings.

Relieve the fuel system pressure. Disconnect the negative battery cable,
then the positive battery cable and remove the battery.

Raise the vehicle and safely support it on jackstands.

Remove the left and right splash shields.

Drain the engine oil and the transmission oil.

Drain the engine coolant.

Disconnect the accelerator cable from the bracket. On automatics
disconnect the throttle cable from the accelerator bracket.

Remove the air cleaner hose and the air cleaner assembly.

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Fig. 3: Unbolt and remove the air cleaner assembly-4A-FE and 7A-FE engines

Remove the coolant reservoir. Remove the radiator and fan assembly.

Fig. 4: Remove the bolts retaining the coolant reservoir stay-4A-FE and 7A-FE engines

Remove the washer reservoir tank.

10.

Fig. 5: Unbolt and pull the washer reservoir from the engine compartment-4A-FE and 7A-FE engines

Disconnect and remove the cruise control actuator.

11.

Label and disconnect the main engine wiring harness from its related
sensors and switches.

12.

Disconnect the following vacuum hoses and connectors from the intake
chamber:

MAP hose from the gas filter

Brake booster vacuum hose

13.

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A/C vacuum hose from the actuator

Disconnect the A/C actuator harness

Disconnect the following hoses and wiring on the RH fender apron side:

Gound strap connector

MAP connector

A/C pressure switch

Engine wire from the apron

14.

Disconnect the following hoses and wiring on the LH fender apron side:

DLC1 connector

Connection from the fender apron

Ground strap from the fender apron

15.

Remove the two bolts and engine relay box. Unsecure the four harness
connectors from the engine relay box.

16.

Remove the charcoal canister.

17.

Fig. 6: Disconnect the hose and remove the charcoal canister from the bracket-4A-FE and 7A-FE
engines

Disconnect the heater hoses.

18.

Fig. 7: Disconnect the heater hoses from the water inlet housing and pipe-4A-FE and 7A-FE engines

Carefully disconnect the fuel inlet and return lines.

19.

If equipped with manual transaxle, unbolt the clutch slave cylinder from

20.

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the bell housing and move the cylinder out of the way. Don't disconnect
any lines or hoses. Disconnect the shift control cables by removing the
two clips, the washers and retainers.

Fig. 8: Unbolt and set aside the slave cylinder, DO NOT disconnect the hydraulic lines-4A-FE and 7A-FE
engines

Fig. 9: On manual transaxles, disconnect the shift control cables-4A-FE and 7A-FE engines

On automatics, disconnect the control cable from the shift lever by
unsecuring the clip and retainer.

21.

Fig. 10: On automatic transaxles, disconnect the control cable from the shift ever-4A-FE and 7A-FE
engines

Disconnect the engine wiring from the cabin. Remove both door scuff
plates, the lower panel with glove box door, radio, center console
cluster finish panel, rear console box and detach any associated wiring.
Disconnect the wiring from the ECU and pull the harness out through
the cowl panel.

22.

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Fig. 11: Exploded view of the removal components in the cabin-4A-FE and 7A-FE engines

Loosen the power steering pump mounting bolt and through bolt.
Remove the drive belt.

23.

Remove the four bolts holding the air conditioner compressor and
remove the compressor. DO NOT loosen or remove any lines or hoses.
Move the compressor out of the way and hang it from a piece of stiff
wire.

24.

Disconnect the speedometer cable from the transaxle.

25.

Disconnect the oxygen sensor. Remove the two bolts from the exhaust
pipe flange and separate the pipe from the exhaust manifold.

26.

Raise the car and support it safely on jackstands.

27.

On 4WD models, disconnect the oil cooler hoses.

28.

Remove the nuts and bolts and separate the halfshafts from the
transaxle.

29.

On 4WD models, disconnect the propeller shaft.

30.

Remove the through bolt from the rear transaxle mount.

31.

Remove the nuts from the center transaxle mount and the rear mount.

32.

Fig. 12: Removing the 2WD center member mounting-4A-FE and 7A-FE engines

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Fig. 13: Removing the 4WD center member mounting-4A-FE engine

Lower the vehicle to the ground and attach the lifting equipment to the
brackets on the engine. Take tension on the hoist line or chain just
enough to support the engine but no more. Hang the engine wires and
hoses on the chain or cable.

33.

Remove the three exhaust hanger bracket nuts and the hanger.
Remove the two center crossmember-to-main crossmember bolts.
Remove the three center crossmember-to-radiator support bolts.

34.

CAUTION

Support the crossmembers with a jack
or jackstands when loosening the bolts.
The pieces are heavy and could fall on
you.

On 4WD models, remove the eight crossmember-to-body bolts, then
remove the two bolts holding the control arm brackets to the
underbody. Remove the two center mount-to-transaxle bolts and
remove the mount. Carefully lower the center mount and crossmember
and remove from under the car.

35.

Fig. 14: 4WD front suspension crossmember mounting-4A-FE engine

At the left engine mount, remove the three bolts and the bracket, then
remove the bolt, two nuts, through bolt and mounting. Remove the
three bolts and the air cleaner bracket.

36.

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Loosen and remove the five bolts and disconnect the mounting bracket
from the transaxle bracket. Remove the through bolt and mounting.

37.

Carefully and slowly raise the engine and transaxle assembly out of the
car. Tilt the transaxle down to clear the right engine mount. Be careful
not to hit the steering gear housing. Make sure the engine is clear of all
wiring, lines and hoses.

38.

Fig. 15: Carefully attach a chain hoist to the engine hangers and lift the assembly out-4A-FE and 7A-FE
engines

Support the engine assembly on a suitable stand; do not allow it to
remain on the hoist for any length of time.

39.

With the engine properly supported, disconnect the reverse light switch
and the neutral safety switch (automatic transaxle).

40.

Remove the rear end cover plate.

41.

If equipped with automatic transaxle, remove the 6 torque converter
mounting bolts.

42.

Remove the starter.

43.

Support the transaxle, remove the retaining bolts in the case and
remove the transaxle from the engine. Pull the unit straight off the
engine; do not allow it to hang partially removed on the shaft. Keep the
automatic transaxle level; if it tilts forward the converter may fall off.

44.

To install:

Before reinstalling the engine in the vehicle, several components must
be reattached or connected.

45.

Attach the chain hoist or lift apparatus to the engine and lower it into
the engine compartment.

46.

Tilt the transaxle downward and lower the engine to clear the left motor
mount. As before, be careful not to hit the power steering housing (rack) or
the throttle position sensor.

Level the engine and align each mount with its bracket. Installation is
the reverse of removal for engine installation. Tighten the components
to the following specifications on 1988-92 models:

RH mounting insulator-to-engine bracket bolt-47 ft. lbs. (64 Nm)

RH mounting insulator-to-engine bracket nut-38 ft. lbs. (52 Nm)

47.

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RH insulator-to-body bracket-64 ft. lbs. (87 Nm)

LH insulator-to-transaxle case bracket-35 ft. lbs. (48 Nm)

RH mounting stay-31 ft. lbs. (42 Nm)

LH mounting stay-15 ft. lbs. (21 Nm)

Engine center member front and rear mounting bolt-64 ft. lbs. (87
Nm)

Engine center member 5 bolts-45 ft. lbs. (61 Nm)

4WD front crossmember lower control arm-152 ft. lbs. (206 Nm)

4WD front crossmember rear bolt-94 ft. lbs. (127 Nm)

Front mounting-to-member-35 ft. lbs. (48 Nm)

Center (2WD) mounting-to-center-38 ft. lbs. (52 Nm)

Rear (2WD) mounting-to-member-38 ft. lbs. (52 Nm)

Rear (4WD) mounting-to-member-42 ft. lbs. (57 Nm)

Front pipe-to-exhaust manifold-46 ft. lbs. (62 Nm)

Tighten the components to the following specifications on 1993-97 models:

Front engine mounting bracket-57 ft. lbs. (77 Nm)

LH mounting bracket-38 ft. lbs. (52 Nm)

LH insulator-to-bracket-41 ft. lbs. (56 Nm)

LH insulator through-bolt-64 ft. lbs. (87 Nm)

LH stay-15 ft. lbs. (21 Nm)

RH insulator-to-body and bracket (A)-47 ft. lbs. (64 Nm)

RH insulator-to-body and bracket (B)-38 ft. lbs. (52 Nm)

RH insulator-to-body and bracket (C)-19 ft. lbs. (25 Nm)

Engine mounting center member-to-body (A)-45 ft. lbs. (61 Nm)

Engine mounting center member-to-body (B)-47 ft. lbs. (64 Nm)

Engine mounting center member-to-body (C)-35 ft. lbs. (48 Nm)

Engine mounting center member-to-body nut-42 ft. lbs. (57 Nm)

Front mounting insulator-to-bracket-64 ft. lbs. (87 Nm)

Fuel inlet hose-22 ft. lbs. (29 Nm)

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Fig. 16: Tighten the RH insulator-to-body and bracket bolts-1993-95 4A-FE and 7A-FE engines

Fig. 17: Tighten the RH insulator-to-body and bracket bolts-1996-97 4A-FE and 7A-FE engines

Fig. 18: Tighten the bolts retaining the center member to the body-4A-FE and 7A-FE engines

Install the battery. Connect the positive cable to the starter terminal,
then to the battery. DO NOT connect the negative battery cable at this
time.

48.

Fill the transmission with the correct amount of fluid.

49.

Refill the engine coolant.

50.

Fill the engine with the correct amount of oil.

51.

52.

Connect the negative battery cable. Start the engine and allow it to
idle. As the engine warms up, shift the automatic transmission into
each gear range allowing it to engage momentarily. After each gear has
been selected, put the shifter in PARK and check the transmission fluid

53.

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level.

Shut the engine OFF and check the engine area carefully for leaks,
particularly around any line or hose which was disconnected during
removal.

54.

Raise and support the front end of the car on jackstands. Replace the
left and right splash shields and lower the vehicle.

55.

With the help of an assistant, reinstall the hood. Adjust the hood for
proper fit and latching. Road test the vehicle for proper operation.

56.

4A-GE Engine

See Figures 19 through 23

Relieve the fuel system pressure. Disconnect the negative battery cable.

With a helper remove the hood (mark hood hinges for correct
installation) from the car. Use care not to damage the paint finish on
the vehicle.

Drain the engine oil.

Drain the cooling system.

Drain the transaxle oil.

Remove the air cleaner assembly.

Fig. 19: Remove the air cleaner assembly-4A-GE engine

Remove the coolant reservoir tank and remove the PCV hose.

Label and remove the heater hoses from the water inlet housing.

Label and disconnect the fuel inlet hose from the fuel filter.

Disconnect the heater and air hoses from the air valve.

10.

Remove the fuel return hose from the pressure regulator.

11.

If equipped with a manual transaxle, remove the slave cylinder from
the housing. Loosen the mounting bolts and move the cylinder out of
the way but do not loosen or remove the fluid hose running to the
cylinder.

12.

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Disconnect the vacuum hose running to the charcoal canister.

13.

Disconnect the shift control cable, the speedometer cable (at the
transaxle) and the accelerator cable (at the throttle body).

14.

If equipped with cruise control, disconnect the cables. Remove the
cruise control actuator by:

Disconnecting the vacuum hose.

Removing the cover and the 3 bolts.

Disconnecting the actuator wiring and removing the actuator.

15.

Remove the ignition coil.

16.

Fig. 20: Unbolt and remove the ignition coil-4A-GE engine

Remove the main engine wiring harness in the following steps:

From inside the car, remove the right side cowl (kick) panel.

Disconnect the wiring harness at junction block 4.

Remove the cover over the Electronic Control Module (ECM) and
carefully disconnect the ECM plugs.

Pull the main wiring harness into the engine compartment.

17.

Fig. 21: Pull the engine wiring through the cowl panel-95 4A-FE and 7A-FE engines

Disconnect the wiring at the number 2 junction block in the engine
compartment.

18.

Remove the engine and transaxle ground straps.

19.

Disconnect the washer valve harness.

20.

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Remove the wiring at the cruise control vacuum pump harness and the
vacuum switch connector.

21.

Remove the hose from the brake vacuum booster.

22.

Depending on equipment, remove the air conditioning compressor
and/or the power steering pump. Note that the units are to be removed
from their mounts and placed out of the way- DO NOT disconnect hoses
and lines from the units.

Remove the power steering pump pulley nut.

Loosen the idler pulley adjusting and pulley bolts.

Remove the four compressor mounting bolts.

Move the compressor aside and suspend it with stiff wire out of
the way.

Loosen the compressor bracket bolts.

Disconnect the oil pressure harness.

Loosen the power steering pump lock bolts and pivot bolts.

Remove the pump and its bracket; suspend it out of the way with
a piece of stiff wire.

23.

Safely raise the vehicle and support on jackstands. Double check the
stands and make sure the vehicle is solidly supported.

24.

Remove the splash shields under the car.

25.

Disconnect the oil cooler hoses.

26.

Fig. 22: Disconnect the oil cooler tubes-4A-GE engine

Disconnect the exhaust pipe from the exhaust manifold.

27.

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Fig. 23: Unbolt and separate the front pipe from the exhaust manifold

Carefully disconnect the wiring from the oxygen sensor.

28.

Remove the cover under the flywheel.

29.

Remove the front and rear motor mounts from the center crossmember.

30.

Remove the center crossmember.

31.

Disconnect the right side control arm at the steering knuckle.

32.

Disconnect the halfshafts from the transaxle.

33.

Lower the vehicle to the ground. Install the engine hoist to the lifting
bracket on the engine. Hang the engine wires and hoses on the lift
chain. Take tension on the hoist sufficient to support the engine; double
check all hoist attaching points.

34.

Disconnect the right side engine mount by removing the bolt.

35.

Disconnect the left side motor mount from the transaxle bracket.

36.

Lift the engine and transaxle from the vehicle. Be careful to avoid
hitting the steering box and the throttle position sensor.

37.

Support the engine assembly on a suitable stand; do not allow it to
remain on the hoist for any length of time.

38.

Disconnect the radiator fan temperature switch harness.

39.

Disconnect the start injector time switch.

40.

Label and remove the vacuum hoses from the Bimetal Vacuum
Switching Valves (BVSV).

41.

Separate the hoses from the water bypass valves, then remove the
water inlet housing assembly.

42.

Label and remove the wiring connectors from the reverse switch, water
temperature sensor, and water temperature switch. If equipped with
automatic transaxle, remove the wiring to the neutral safety switch and
transaxle solenoid.

43.

If equipped with automatic transaxle, remove the 6 torque
converter-to-flexplate bolts.

44.

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Remove the starter along with its cable and connector.

45.

Support the transaxle, remove the retaining bolts in the case, then
separate the transaxle from the engine. Pull the unit straight off the
engine; do not allow it to hang partially removed on the shaft. Keep the
automatic transaxle level; if it tilts forward the converter may fall off.

46.

To install:

Install the engine in the reverse order of removal paying particular
attention to the following.

47.

Before reinstalling the engine in the car, several components must be
reattached or connected. Install the transaxle to the engine; tighten the
12mm bolts to 47 ft. lbs. (64 Nm) and the 10mm bolts to 34 ft. lbs. (46
Nm). Tighten other components to the following specifications:

Starter mounting bolts-29 ft. lbs. (39 Nm)

Right motor mount and through bolt-58 ft. lbs. (78 Nm).

Engine mounting automatics-38 ft. lbs. (52 Nm)

Engine mounting bracket-to-transaxle-45 ft. lbs. (61 Nm)

Engine mounting stay LH-15 ft. lbs. (21 Nm)

Engine mounting LH-to-transaxle manual-38 ft. lbs. (52 Nm)

Engine mounting stay RH-31 ft. lbs. (42 Nm)

Engine mounting RH-to-engine manual-nut-38 ft. lbs. (52 Nm)

Engine mounting RH-to-engine manual bolt-47 ft. lbs. (64 Nm)

Engine mounting bolt front-35 ft. lbs. (48 Nm)

Engine mounting bolt center-38 ft. lbs. (52 Nm)

Engine mounting bolt rear-42 ft. lbs. (57 Nm)

Engine rear mounting bolt-64 ft. lbs. (87 Nm)

Engine front mounting bolt-64 ft. lbs. (87 Nm)

Power steering pump pulley bolt-28 ft. lbs. (38 Nm)

48.

Fill the transaxle with the correct amount of oil, and fill the engine with
oil.

49.

Fill the cooling system with the proper amount of fluid.

50.

51.

Connect the negative battery cable.

52.

Start the engine and allow it to reach normal operating temperature.
Check carefully for leaks. Shut the engine OFF.

53.

Raise the front end of the car, support on jackstands and install the
splash shields below the car.

54.

AutoZone.com | Repair Info | Toyota Corolla 1988-1997 Repair Guide | ...

http://www.autozone.com/az/cds/en_us/0900823d/80/16/a0/93/0900823...

19 of 19

9/28/2007 3:58 PM

Lower the car to the ground. With your helper, install the hood and
adjust it for proper fit and latching. Road test the vehicle for proper
operation.

55.

The material provided in the Repair Guides is under license from Delmar Publishers. Any part of these
publications may not be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording, storage in an information retrieval system, or otherwise,
without the

Written Permission

of the publisher. Any unauthorized commercial use, resale or mailing list

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