Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM100000001O1S8
Model Year Start: 2021 Model: Corolla Prod Date Range: [04/2020 - 09/2022]
Title: 2ZR-FXE (ENGINE MECHANICAL): CYLINDER HEAD GASKET: 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 cylinder head gasket 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

2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; PRE-COLLISION: PRE-COLLISION SYSTEM (for HV Model): INITIALIZATION

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

2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): UTILITY for 2ZR-FXE (for Nickel Metal Hydride Battery)

2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY with P610): UTILITY 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

2020 - 2025 MY Corolla Corolla HV [01/2019 -        ]; 2ZR-FXE (ENGINE CONTROL): SFI SYSTEM: REGISTRATION

  • Replacement of throttle body assembly
  • Replacement of cylinder head sub-assembly
  • Replacement of camshaft (for intake or exhaust camshaft)
  • Replacement of camshaft timing gear assembly
  • Replacement of fuel injector assembly
  • Replacement of ignition coil assembly
  • Replacement of EGR valve assembly
  • Gas leak from exhaust system is repaired

Inspection After Repair

  • Poor idle, etc.
  • Engine start function, etc.

2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

Front wheel alignment adjustment

  1. Clear zero point calibration data
  2. 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

2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): CALIBRATION

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. INSTALL ENGINE TO ENGINE STAND

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL

2. REMOVE ENGINE HANGERS

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE WATER OUTLET

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

4. REMOVE EGR PIPE ASSEMBLY

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

5. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL+

7. REMOVE MANIFOLD STAY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL+

8. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL+

9. REMOVE INTAKE MANIFOLD

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

10. REMOVE ENGINE OIL LEVEL DIPSTICK

Click here 2020 - 2025 MY Corolla Corolla HV [01/2019 -        ]; 2ZR-FXE (COOLING): THERMOSTAT: REMOVAL+

11. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

Click here 2020 - 2025 MY Corolla Corolla HV [01/2019 -        ]; 2ZR-FXE (COOLING): THERMOSTAT: REMOVAL+

12. REMOVE WATER BY-PASS PIPE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

13. REMOVE PURGE VALVE (PURGE VSV)

Click here 2020 - 2025 MY Corolla Corolla HV [01/2019 -        ]; 2ZR-FXE (EMISSION CONTROL): PURGE VALVE: REMOVAL+

14. REMOVE FUEL VAPOR FEED PIPE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL+

15. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (FUEL): FUEL INJECTOR: REMOVAL+

16. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (FUEL): FUEL INJECTOR: REMOVAL+

17. REMOVE FUEL INJECTOR ASSEMBLY

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (FUEL): FUEL INJECTOR: REMOVAL+

18. REMOVE IGNITION COIL ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE CONTROL): IGNITION COIL AND SPARK PLUG: REMOVAL+

19. REMOVE CAMSHAFT POSITION SENSOR

Click here 2020 - 2025 MY Corolla Corolla HV [01/2019 -        ]; 2ZR-FXE (ENGINE CONTROL): CAMSHAFT POSITION SENSOR: REMOVAL+

20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

21. REMOVE CYLINDER HEAD COVER GASKET

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

22. REMOVE SPARK PLUG TUBE GASKET

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

23. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

24. REMOVE CRANKSHAFT PULLEY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): FRONT CRANKSHAFT OIL SEAL: REMOVAL+

25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

26. REMOVE TIMING CHAIN COVER OIL SEAL

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): FRONT CRANKSHAFT OIL SEAL: REMOVAL+

27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

28. REMOVE CHAIN TENSIONER SLIPPER

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

29. REMOVE NO. 1 CHAIN VIBRATION DAMPER

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

30. REMOVE NO. 2 CHAIN VIBRATION DAMPER

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

31. REMOVE CHAIN SUB-ASSEMBLY

(a) Using a wrench to hold the hexagonal portion of the camshaft, turn the camshaft timing gear assembly counterclockwise to loosen the chain sub-assembly between the camshaft timing sprocket and camshaft timing gear assembly.

*a

Loosen the Chain Sub-assembly

*b

Place the chain sub-assembly on the non-toothed portion of camshaft timing gear assembly

(b) With the chain sub-assembly loosened, separate the chain sub-assembly from the teeth of the camshaft timing gear assembly and place it on the non-toothed portion of camshaft timing gear assembly.

(c) Turn the camshaft clockwise to return it to its original position and remove the chain sub-assembly.

32. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

34. REMOVE CAMSHAFT TIMING SPROCKET

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

35. REMOVE CAMSHAFT BEARING CAP

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

36. REMOVE NO. 2 CAMSHAFT

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): CAMSHAFT: REMOVAL+

37. REMOVE CAMSHAFT

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

38. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

39. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

40. REMOVE VALVE LASH ADJUSTER ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

41. REMOVE VALVE STEM CAP

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

42. REMOVE CYLINDER HEAD SUB-ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

43. REMOVE CYLINDER HEAD GASKET

(a) Remove the cylinder head gasket from the cylinder block sub-assembly.

44. INSPECT CYLINDER HEAD SET BOLT

Click here 2020 - 2025 MY Corolla Corolla HV [01/2019 -        ]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: INSPECTION+