2ZR-FAE (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2020 MY Corolla [01/2019

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001G45K
Model Year Start: 2020	Model: Corolla	Prod Date Range: [01/2019 - 03/2019]
Title: 2ZR-FAE (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2020 MY Corolla [01/2019 - 03/2019]

INSTALLATION

CAUTION / NOTICE / HINT

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.

HINT:

Perform "Inspection After Repair" after replacing the engine assembly.

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PROCEDURE

1. INSTALL ENGINE HANGERS

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2. REMOVE ENGINE FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

3. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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4. INSTALL GENERATOR ASSEMBLY

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5. INSTALL V-RIBBED BELT

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6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

Click here

7. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

Click here

8. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

Click here

9. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

Click here

10. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)

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11. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY (for Manual Transaxle)

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

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13. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

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14. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

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15. INSTALL BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)

Click here

16. INSTALL ENGINE ASSEMBLY (for CVT)

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17. INSTALL ENGINE ASSEMBLY (for Manual Transaxle)

Click here

18. INSTALL WATER BY-PASS HOSE ASSEMBLY (for CVT)

(a) Install the water by-pass hose assembly to the oil cooler and slide the 2 clips to secure it.

(b) Install the water by-pass hose assembly to the No. 3 water by-pass pipe and cylinder head sub-assembly and slide the 2 clips to secure it.

19. INSTALL ENGINE WIRE

(a) Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.

20. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Install the flywheel housing side cover to the cylinder block sub-assembly.

21. INSTALL STARTER ASSEMBLY

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22. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

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

(a) Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

*a	Temporarily Tighten

(b) Install the 2 bolts and nut in the order shown in the illustration.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(c) Connect the air conditioner tube and accessory assembly to the engine mounting insulator sub-assembly RH with the bolt and nut.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

(d) Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

Torque:

10.5 N·m {107 kgf·cm, 8 ft·lbf}

23. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

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

(a) Temporarily install the engine mounting insulator LH to the vehicle.

*A	for CVT
*B	for Manual Transaxle
*a	Temporarily Tighten

(b) Install the 4 bolts and nut in the order shown in the illustration.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

24. REMOVE ENGINE HANGERS

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25. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket with the bolt.

Torque:

39 N·m {398 kgf·cm, 29 ft·lbf}

(b) Connect the air fuel ratio sensor connector.

26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.

NOTICE:

Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.
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 oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

(b) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:

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

Torque:

141 N·m {1438 kgf·cm, 104 ft·lbf}

(d) Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

NOTICE:

While holding the nut in place, tighten the bolt.

(e) Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

41 N·m {418 kgf·cm, 30 ft·lbf}

27. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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28. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

29. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)

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30. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover to the stiffening crankcase assembly.

31. CONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)

(a) Connect the No. 1 clutch hose to the clutch flexible hose bracket with a new clip.

(b) Using a 10 mm union nut wrench, connect the bleeder clutch release tube to the No. 1 clutch hose.

Torque:

Specified tightening torque :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

*a	10 mm Union Nut Wrench
*b	Torque Wrench Fulcrum Length

32. INSTALL DRIVE SHAFT ASSEMBLY

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33. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

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34. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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35. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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36. INSTALL COLUMN HOLE COVER SILENCER SHEET

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37. CONNECT SUCTION HOSE SUB-ASSEMBLY

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38. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

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39. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel pipe.

Click here

(b) Engage the claw and install the No. 1 fuel pipe clamp.

40. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose to the No. 1 water by-pass pipe and slide the clip to secure it.

41. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose to the No. 3 water by-pass hose and slide the clip to secure it.

(b) Engage the clamp.

42. CONNECT CHECK VALVE TO CONNECTOR TUBE HOSE

Click here

43. CONNECT FUEL VAPOR FEED HOSE

(a) Connect the fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.

44. CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE (for CVT)

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45. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Install the transmission control cable assembly to the control cable bracket assembly with 2 new clips (B).

NOTICE:

Make sure that the paint marks on the transmission control cable assembly are aligned with the slits in the control cable bracket assembly before installing the clips.

*a	Paint Mark

(b) Connect the transmission control cable assembly to the manual transaxle assembly with the 2 clips (A).

46. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

47. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.

48. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly to the vehicle with the 3 bolts.

Torque:

15.4 N·m {157 kgf·cm, 11 ft·lbf}

(b) Engage the clamp to connect the engine wire to the battery clamp sub-assembly.

49. CONNECT WIRE HARNESS

(a) Connect the engine wire to the positive (+) battery terminal with the 3 nuts.

Torque:

7.6 N·m {77 kgf·cm, 67 in·lbf}

(b) Connect the engine wire to the battery clamp sub-assembly with the bolt and nut.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

50. INSTALL ECM

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51. INSTALL BATTERY

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52. BLEED CLUTCH LINE (for Manual Transaxle)

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53. ADD ENGINE OIL

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54. ADD ENGINE COOLANT

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55. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

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56. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

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57. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

for HFO-1234yf(R1234yf):
Click here
for HFC-134a(R134a):
Click here

58. WARM UP COMPRESSOR

for HFO-1234yf(R1234yf):
Click here
for HFC-134a(R134a):
Click here

59. INSPECT TRANSAXLE OIL (for Manual Transaxle)

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60. ADJUST SHIFT LEVER POSITION (for Manual Transaxle)

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61. INSPECT SHIFT LEVER POSITION (for CVT)

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62. ADJUST SHIFT LEVER POSITION (for CVT)

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63. INSPECT FOR ENGINE OIL LEAK

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64. INSPECT FOR COOLANT LEAK

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65. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK (for CVT)

66. INSPECT FOR MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)

67. INSPECT FOR REFRIGERANT LEAK

for HFO-1234yf(R1234yf):
Click here
for HFC-134a(R134a):
Click here

68. INSPECT FOR FUEL LEAK

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69. INSPECT FOR EXHAUST GAS LEAK

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70. CHECK ENGINE OIL LEVEL

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71. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL

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72. INSTALL REAR ENGINE UNDER COVER LH

(a) Type A:

(1) Install the rear engine under cover LH to the vehicle with the 4 clips.

(2) Install the screw.

(b) Type B:

(1) Install the rear engine under cover LH to the vehicle with the 5 clips.

(2) Install the screw.

73. INSTALL REAR ENGINE UNDER COVER RH

(a) Type A:

(1) Install the rear engine under cover RH to the vehicle with the 4 clips.

(2) Install the screw.

(b) Type B:

(1) Install the rear engine under cover RH to the vehicle with the 5 clips.

(2) Install the screw.

74. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

(a) Install the No. 1 engine under cover assembly to the vehicle with the 10 clips.

(b) Install the 4 bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

75. INSTALL FRONT WHEELS

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76. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

77. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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78. PERFORM INITIALIZATION

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79. INSPECT IGNITION TIMING

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80. INSPECT ENGINE IDLE SPEED

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81. INSPECT CO/HC

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82. CHECK SPEED SENSOR SIGNAL

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