M20A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2019 MY Corolla Corolla Hatchback [06/2018

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001CJJH
Model Year Start: 2019	Model: Corolla Hatchback	Prod Date Range: [06/2018 - 01/2019]
Title: M20A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2019 MY Corolla Corolla Hatchback [06/2018 - 01/2019]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Control System
		Pre-collision system
		Lighting System (w/ AFS)(EXT)
	Initialize back door lock	Power Door Lock Control System
Replacement of ECM	Vehicle Identification Number (VIN) registration	MIL comes on
	ECU communication ID registration (Immobiliser system)	Engine start function
	Code registration (Smart Key System (for Start Function))	Wireless Door Lock Control System Smart Key System (for Entry Function) Smart Key System (for Start Function) Steering lock function
Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Replacement of continuously variable transaxle assembly	Input transaxle compensation code into TCM Perform reset memory Deceleration sensor zero point calibration CVT oil pressure calibration Perform road test to allow TCM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization for Registration
Replacement of ECM	Perform reset memory CVT oil pressure calibration Perform road test to allow TCM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization for Registration
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement)	Perform headlight ECU sub-assembly LH initialization	Lighting system (w/ AFS)(EXT)
Front wheel alignment adjustment	Perform "Reset Memory". Perform acceleration sensor zero point calibration and store system information memorization.	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates
CVT fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

*a	An Object Exceeding Weight Limit of Engine Lifter

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

NOTICE:

After the engine switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Audio and Visual System)
After the engine switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Navigation System)

PROCEDURE

1. PRECAUTION

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2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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3. DISCHARGE FUEL SYSTEM PRESSURE

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4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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6. REMOVE BATTERY

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7. SECURE STEERING WHEEL

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8. REMOVE FRONT WHEELS

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9. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

(a) Remove the 4 bolts, 10 clips and No. 1 engine under cover assembly from the vehicle.

*A	Type A
*B	Type B

10. REMOVE REAR ENGINE UNDER COVER LH

(a) Remove the screw, 4 clips and rear engine under cover LH from the vehicle.

for CVT

for Manual Transaxle

11. REMOVE REAR ENGINE UNDER COVER RH

(a) Remove the screw, 4 clips and rear engine under cover RH from the vehicle.

12. DRAIN ENGINE OIL

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13. DRAIN ENGINE COOLANT

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14. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

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15. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

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16. REMOVE ECM

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17. DISCONNECT ENGINE WIRE

(a) Remove the 2 bolts to separate the engine wire from the vehicle.

(b) Remove the 3 nuts to separate the engine wire from the positive (+) battery terminal.

18. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Disengage the clamp to separate the engine wire from the battery clamp sub-assembly.

(b) Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

19. DISCONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE (for CVT)

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20. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Remove the 2 clips (A) to disconnect the transmission control cable assembly from the manual transaxle assembly.

(b) Remove the 2 clips (B) to disconnect the transmission control cable assembly from the control cable bracket assembly.

21. DISCONNECT NO. 1 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 1 radiator hose from the water outlet.

22. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disengage the clamp to separate the No. 2 radiator hose.

(b) Slide the clip and disconnect the No. 2 radiator hose from the radiator assembly.

23. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR

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24. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Disengage the clamp to separate the No. 1 fuel vapor feed hose.

(b) Slide the clip and disconnect the No. 1 fuel vapor feed hose from the vacuum surge tank.

25. DISCONNECT INLET HEATER WATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the inlet heater water hose.

*a	Retainer
	Pull out
	Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected flow shutting valve (water valve) and inlet heater water hose connector with plastic bags to prevent damage and contamination.

26. DISCONNECT OUTLET HEATER WATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the outlet heater water hose.

*a	Retainer
	Pull out
	Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector with plastic bags to prevent damage and contamination.

27. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Disengage the clamp to separate the fuel tube sub-assembly.

(b) Disconnect the fuel tube sub-assembly from the fuel pump assembly.

Click here

28. DISCONNECT NO. 2 WATER BY-PASS HOSE

(a) Slide the hose clip and disconnect the No. 2 water by-pass hose from the No. 2 water by-pass pipe assembly.

29. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

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30. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

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31. REMOVE COLUMN HOLE COVER SILENCER SHEET

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32. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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33. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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34. REMOVE FRONT FLOOR COVER LH

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35. REMOVE FRONT FLOOR COVER RH

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36. REMOVE FRONT FLOOR CENTER BRACE

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37. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

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38. REMOVE DRIVE SHAFT ASSEMBLY

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39. DISCONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)

(a) Using a 10 mm union nut wrench, disconnect the bleeder to flexible hose tube from the No. 1 clutch hose.

(b) Remove the clip and disconnect the No. 1 clutch hose from the clutch flexible hose bracket.

40. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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41. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

42. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on an engine lifter.

NOTICE:

Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle and front suspension crossmember sub-assembly level.
Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

(b) Remove the 2 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

(1) Remove the 3 bolts, through bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket LH.

NOTICE:

While holding the nut in place, loosen the bolt.

(d) for Manual Transaxle:

(1) Remove the 4 bolts, through bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket LH.

NOTICE:

While holding the nut in place, loosen the bolt.

(e) Remove the 4 bolts to separate the front suspension crossmember sub-assembly from the vehicle.

(f) Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

NOTICE:

Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

43. REMOVE FUEL DELIVERY GUARD

(a) Remove the bolt and fuel delivery guard from the engine mounting bracket RH.

44. INSTALL ENGINE HANGER

(a) Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

No. 1 Engine Hanger	12281-25030
No. 2 Engine Hanger	12282-25010
Bolt	91552-F1040

*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger
	Bolt

(b) Attach an engine sling device and hang the engine assembly with transaxle with a chain block.

NOTICE:

Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.

45. REMOVE ENGINE MOUNTING INSULATOR LH

HINT:

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

(a) Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle.

*A	for CVT
*B	for Manual Transaxle

46. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(a) Remove the 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle.

(b) Remove the bolt and disconnect the air conditioner tube and accessory assembly.

47. REMOVE STARTER ASSEMBLY

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48. REMOVE FLYWHEEL HOUSING SIDE COVER

(a) Remove the flywheel housing side cover from the cylinder block sub-assembly.

49. REMOVE ENGINE WIRE

(a) Disconnect all the clamps and connectors and remove the engine wire from the engine assembly with transaxle.

50. REMOVE MANIFOLD STAY

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51. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

for Manual Transaxle:
Click here
for CVT:
Click here

52. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Disengage the 2 claws and guide to remove the flywheel housing under cover from the cylinder block sub-assembly.

Remove in this Direction

53. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)

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54. DISCONNECT WATER INLET HOSE (for CVT)

(a) Slide the hose clip and disconnect the water inlet hose from the No. 1 water by-pass hose assembly.

55. DISCONNECT WATER BY-PASS HOSE ASSEMBLY (for CVT)

(a) Slide the hose clip and disconnect the water by-pass hose assembly from the No. 3 water by-pass pipe sub-assembly.

56. REMOVE ENGINE ASSEMBLY (for CVT)

(a) Remove the 8 bolts and engine assembly from the continuously variable transaxle assembly.

NOTICE:

To prevent damage to the 2 knock pins, do not pry between the continuously variable transaxle assembly and engine assembly.

HINT:

Bolt (A), (B): Remove from continuously variable transaxle assembly side.
Bolt (C): Remove from engine assembly side.

57. REMOVE ENGINE ASSEMBLY (for Manual Transaxle)

(a) Remove the 8 bolts and engine assembly from the manual transaxle assembly.

NOTICE:

To prevent damage to the 2 knock pins, do not pry between the manual transaxle assembly and engine assembly.

HINT:

Bolt (A): Remove from the manual transaxle assembly side.
Bolt (B): Remove from the engine assembly side.

58. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

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59. REMOVE BLEEDER TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

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60. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY (for Manual Transaxle)

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61. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY TO BLEEDER TUBE (for Manual Transaxle)

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62. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

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63. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

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64. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

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65. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

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66. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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67. REMOVE V-RIBBED BELT

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68. REMOVE GENERATOR ASSEMBLY

for Manual Transaxle:
Click here
for CVT
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69. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

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70. INSTALL ENGINE TO ENGINE STAND

(a) Install the engine assembly to an engine stand.

71. REMOVE ENGINE HANGER

(a) Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.