M20A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2020 MY Corolla Corolla Hatchback [01/2019

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001HCA6
Model Year Start: 2020	Model: Corolla Hatchback	Prod Date Range: [01/2019 - 03/2019]
Title: M20A-FKS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2020 MY Corolla Corolla Hatchback [01/2019 - 03/2019]

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 unit 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
1: for Hatchback 2: w/o Smart Key System *3: w/ Smart Key System
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Control System (for Gasoline Model)
		Pre-collision System (for Gasoline Model)
		Lighting System (w/ AFS)(EXT)
	Initialize back door lock*1	Power Door Lock Control System (for Hatchback, Gasoline Model)
Replacement of ECM	Vehicle Identification Number (VIN) registration	MIL comes on
Replacement of ECM	ECU communication ID registration (Immobiliser system)	Engine start function
Replacement of ECM*3	Code registration (Smart Key System (for Gasoline Model, Start Function))	Wireless Door Lock Control System (for Gasoline Model with Smart Key System) Smart Key System (for Gasoline Model, Entry Function) Smart Key System (for Gasoline Model, Start Function) Steering lock function
Replacement of ECM*2	Code registration (Immobiliser system)	Engine start
Replacement of engine assembly Gas leak from exhaust system is repaired Replacement of throttle body with motor assembly Replacement of cam timing control motor with EDU assembly Removal and installation of a cam timing control motor with EDU assembly Replacement of camshaft timing gear assembly Removal and installation of a camshaft timing gear assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing exhaust gear assembly Replacement of port fuel injector assembly Replacement of direct fuel injector assembly Replacement of fuel pump assembly (for high pressure side) Replacement of engine coolant temperature sensor Replacement of spark plug Replacement of ignition coil assembly Replacement of EGR valve assembly Replacement of knock control sensor Replacement of air fuel ratio sensor (sensor 2)	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	w/ Electric Parking Brake System: w/o Electric Parking Brake System:
CVT fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

NOTICE:

After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Audio and Visual System (for Gasoline Model))
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)
This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.
Click here

PROCEDURE

1. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE:

Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

(a) Remove the 2 bolts and V-ribbed belt tensioner assembly from the No. 2 timing chain cover assembly.

2. DISCONNECT NO. 2 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

3. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

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

(b) Remove the bolt and No. 2 water by-pass pipe sub-assembly from the water hose clamp bracket.

4. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(a) Remove the bolt to disconnect the flow shutting valve (water by-pass hose assembly) from the water hose clamp bracket.

*A	for CVT
*B	for Manual Transaxle

(b) Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.

HINT:

Use a container to catch any engine coolant which flows out of the flow shutting valve (water by-pass hose assembly) and water by-pass outlet sub-assembly.

5. REMOVE WATER HOSE CLAMP BRACKET

(a) Remove the bolt and water hose clamp bracket from the water hose clamp bracket.

(b) Remove the 2 bolts and water hose clamp bracket from the camshaft housing sub-assembly.

6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Click here

7. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

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8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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9. REMOVE THROTTLE BODY GASKET

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10. REMOVE EGR COOLER ASSEMBLY

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11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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12. REMOVE EGR VALVE ASSEMBLY

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13. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.

(b) Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.

14. REMOVE INTAKE MANIFOLD STAY

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15. REMOVE INTAKE MANIFOLD

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16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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17. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

Click here

(b) Remove the fuel pipe clamp from the fuel tube connector.

Click here

18. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using an 8 mm socket wrench, remove the bolt.

(b) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

19. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

20. REMOVE NO. 1 WATER BY-PASS HOSE ASSEMBLY

(a) for Manual Transaxle:

(1) Slide the clip and remove the plug from the No. 1 water by-pass hose assembly.

(b) Remove the bolt.

(c) Slide the 2 clips and remove the No. 1 water by-pass hose assembly from the water inlet with thermostat sub-assembly and cylinder head sub-assembly.

21. REMOVE SENSOR WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 3 clamps.

22. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 2 clamps.

23. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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24. REMOVE FUEL DELIVERY SPACER

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25. REMOVE INJECTOR VIBRATION INSULATOR

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26. REMOVE NO. 5 ENGINE WIRE

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27. REMOVE PORT FUEL INJECTOR ASSEMBLY

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28. REMOVE FUEL DELIVERY PIPE

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29. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

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30. REMOVE FUEL INJECTOR SEAL

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31. REMOVE IGNITION COIL ASSEMBLY

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32. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the engine oil level dipstick.

(b) Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the cylinder head sub-assembly.

33. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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34. REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

(a) Remove the 4 bolts, engine water pump assembly (water inlet housing) and gasket from the cylinder block sub-assembly.

35. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 2 bolts and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.

36. REMOVE PURGE VALVE (PURGE VSV)

Click here

37. REMOVE VACUUM SURGE TANK

(a) Remove the bolt and vacuum surge tank from the vacuum surge tank bracket.

38. REMOVE VACUUM SURGE TANK BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and vacuum surge tank bracket from the camshaft housing sub-assembly.

39. REMOVE NO. 2 VENTILATION HOSE

(a) Slide the clip and remove the No. 2 ventilation hose from the cylinder head cover sub-assembly.

40. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.

(b) Using an 8 mm socket wrench, remove the bolt and wire harness clamp bracket from the camshaft housing sub-assembly.

41. REMOVE STUD BOLT

(a) Using an E8 "TORX" socket wrench, remove the stud bolt from the timing chain cover assembly.