2ZR-FXE (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2021 - 2022 MY Corolla Corolla HV [04/2020

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001N6AZ
Model Year Start: 2021	Model: Corolla	Prod Date Range: [04/2020 - 09/2022]
Title: 2ZR-FXE (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]

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 Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Disconnect cable from negative auxiliary battery terminal	Perform steering sensor zero point calibration	Lane Control System
Disconnect cable from negative auxiliary battery terminal	Perform steering sensor zero point calibration	Pre-collision System
Replacement of inverter with converter assembly	Resolver learning	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	for 2ZR-FXE (for Nickel Metal Hydride Battery) for 2ZR-FXE (for Lithium-ion Battery)
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver
Replacement of ECM	Vehicle Identification Number (VIN) registration	MIL comes on
Replacement of throttle body assembly Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Front wheel alignment adjustment	Clear zero point calibration data Perform yaw rate and acceleration sensor zero point calibration	DTCs are stored ABS warning light illuminates Brake warning light / yellow (minor malfunction) illuminates Slip indicator light illuminates VSC disabled or malfunctions

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

PROCEDURE

1. PRECAUTION

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2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

for HFO-1234yf(R1234yf):
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for HFC-134a(R134a):
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3. DISCHARGE FUEL SYSTEM PRESSURE

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4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

5. SECURE STEERING WHEEL

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6. REMOVE FRONT WHEELS

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7. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

(a) Remove the 4 bolts.

(b) Remove the 10 clips and No. 1 engine under cover assembly from the vehicle.

8. REMOVE REAR ENGINE UNDER COVER LH

(a) Type A:

(1) Remove the screw.

(2) Remove the 4 clips and rear engine under cover LH from the vehicle.

(b) Type B:

(1) Remove the screw.

(2) Remove the 5 clips and rear engine under cover LH from the vehicle.

9. REMOVE REAR ENGINE UNDER COVER RH

(a) Type A:

(1) Remove the screw.

(2) Remove the 4 clips and rear engine under cover RH from the vehicle.

(b) Type B:

(1) Remove the screw.

(2) Remove the 5 clips and rear engine under cover RH from the vehicle.

10. DRAIN ENGINE OIL

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11. DRAIN ENGINE COOLANT (for Engine)

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12. DRAIN HYBRID TRANSAXLE FLUID

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13. DISCONNECT NO. 8 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 8 water by-pass hose from the No. 4 water by-pass hose.

14. REMOVE RADIATOR SUPPORT OPENING COVER

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15. REMOVE INLET NO. 2 AIR CLEANER

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16. REMOVE THROTTLE BODY ASSEMBLY

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17. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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19. REMOVE AIR CLEANER BRACKET

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20. REMOVE INLET NO. 1 AIR CLEANER

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21. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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22. DISCONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

(a) Remove the nut and disconnect the floor shift transmission control select cable from the control shaft lever.

(b) Remove the clip and disconnect the floor shift transmission control select cable from the No. 1 transmission control cable bracket.

(c) Remove the bolt to disconnect the floor shift transmission control select cable from the cylinder head cover sub-assembly.

23. DISCONNECT NO. 3 RADIATOR HOSE

(a) Remove the 2 bolts from the hybrid vehicle transaxle assembly.

(b) Slide the clip and disconnect the No. 3 radiator hose from the water outlet.

24. DISCONNECT NO. 2 RADIATOR HOSE

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

25. DISCONNECT INLET HEATER WATER HOSE

(a) Slide the clip and disconnect the inlet heater water hose.

26. DISCONNECT OUTLET HEATER WATER HOSE

(a) Slide the clip and disconnect the outlet heater water hose.

27. DISCONNECT FUEL VAPOR FEED HOSE

(a) Slide the clip and disconnect the fuel vapor feed hose from the fuel vapor feed pipe.

28. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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29. DISCONNECT INLET HYBRID RADIATOR HOSE

(a) Slide the clip and disconnect the inlet hybrid radiator hose from the motor cooling cooler.

NOTICE:

Do not pull the inlet hybrid radiator hose with excessive force to deform the motor cooling cooler pipe.
If the motor cooling cooler pipe is deformed replace it because using a deformed pipe can cause coolant leakage.

30. DISCONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE

(a) Slide the clip and disconnect the outlet No. 1 hybrid water pump hose from the motor cooling cooler.

NOTICE:

Do not pull the outlet No. 1 hybrid water pump hose with excessive force to deform the motor cooling cooler pipe.
If the motor cooling cooler pipe is deformed replace it because using a deformed pipe can cause coolant leakage.

31. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

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32. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

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33. DISCONNECT NO. 3 ENGINE WIRE

(a) Remove the 3 bolts.

(b) Disengage the clamp and disconnect the No. 3 engine wire from the hybrid vehicle transaxle assembly.

34. REMOVE COLUMN HOLE COVER SILENCER SHEET

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35. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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

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37. REMOVE FRONT FLOOR COVER LH

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38. REMOVE FRONT FLOOR COVER RH

HINT:

Use the same procedure as for the LH side.

39. REMOVE FRONT FLOOR CENTER BRACE

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

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41. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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42. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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43. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

44. 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.

(d) Remove the bolt and No. 2 engine mounting stay LH.

(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.

45. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Disengage the 3 clamps.

(b) Remove the bolt and wire harness clamp bracket from the cylinder head sub-assembly.

46. INSTALL ENGINE HANGERS

(a) Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

No. 1 Engine Hanger	12281-37070
No. 2 Engine Hanger	12282-37060
Bolt	91552-81050

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

(b) Using an engine sling device and engine lifter, secure the engine assembly with transaxle.

NOTICE:

Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.
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.

47. 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.

48. 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, nut and disconnect the air conditioner tube and accessory assembly.

49. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

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50. REMOVE STARTER HOLE INSULATOR

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51. REMOVE FLYWHEEL HOUSING SIDE COVER

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52. REMOVE ENGINE WIRE

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

53. REMOVE ENGINE ASSEMBLY

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54. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

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55. REMOVE FLYWHEEL SUB-ASSEMBLY

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56. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

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

57. REMOVE ENGINE HANGERS

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