Gearbox removal & installation: Toyota Aygo 1.0 VVT-i (1KR-FE)

🧭 Before you start

Fits: platform codes 1.0, VVT-I

• Opens: coolant, gearbox oil, fuel

Don't miss

• Before disconnecting the battery cable, ensure that the ignition key is in the OFF position
• Remove the engine wiring loom (do not disconnect)

🔧 Engine codes this applies to

📋 Procedure

Preparation and removal

1. Before disconnecting the battery cable, ensure that the ignition key is in the OFF position
2. Disconnect the battery earth cable
3. Remove the front wheels
4. Front drive shaft to wheel bearing housing:
5. Remove the drive shaft nuts

6. Disconnect the track rod ends
7. Lower arm ball joints:
8. Disconnect the lower arm ball joints
9. Remove the front bumper
10. All vehicles:
11. Remove the scuttle panel grille
12. Remove the air inlet duct
13. Remove the battery
14. Move the fuse box holder aside
15. Remove the battery tray
16. Disconnect the cables from the battery clamp
17. Disconnect the fuse box connections
18. Remove the fuse box
19. Remove the engine wiring loom (do not disconnect)
20. Unclip the wiring from the gearbox
21. Disconnect the vacuum hose from the brake servo
22. Disconnect the heater hoses
23. Disconnect the fuel lines
24. Disconnect the earth cable from the gearbox
25. Disconnect the gearbox operating linkage
26. Remove the torque rod
27. Remove the front exhaust pipe
28. Vehicles with air conditioning:
29. Vehicles with air conditioning:
30. Disconnect the air-conditioning compressor and place it aside
31. Remove the condenser
32. Engine mounts
33. Remove the engine/gearbox supports
34. Remove the engine/gearbox from under the vehicle

Installation and checks

35. Tighten the bolts
36. Refit the exhaust pipe
37. Vehicles with air conditioning:
38. Refit the condenser
39. Refit the radiator
40. All vehicles:
41. Refit the heater hoses
42. Reconnect the gear-shift cables to the gearbox
43. Reconnect all the cables, hoses and lines to the engine and gearbox
44. Refit the battery tray
45. Refit the fuse box to the mounting bracket
46. Refit the battery
47. Refit the scuttle panel grille
48. Reconnect the lower arm ball joints
49. Refit the drive shafts
50. Tighten the drive shaft nuts
51. Vehicles with air conditioning:
52. Refit the front bumper
53. All vehicles:
54. Refit the front wheels
55. Refill the gearbox
56. Refill the cooling system
57. Bleed the system
58. Reconnect the battery

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