Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM100000001O2PO
Model Year Start: 2021 Model: Corolla Prod Date Range: [04/2020 - 09/2022]
Title: 2ZR-FXE (EMISSION CONTROL): EGR VALVE: 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 EGR valve 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

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Control System (for HV Model)

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

Pre-collision System (for HV Model)

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 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 Lithium-ion Battery

Replacement of ECM

Vehicle Identification Number (VIN) or frame number registration

MIL comes on

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

  • Replacement of EGR valve assembly
  • Gas leak from exhaust system is repaired

Inspection after repair
  • Poor idle, etc.
  • Engine start function, etc.

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    for Nickel Metal Hydride Battery: Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): PRECAUTION

    for Lithium-ion Battery: Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY with P610): PRECAUTION

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
  • Be sure to wear insulating gloves when working on high voltage wiring or components.
  • If work is performed without wearing insulating gloves, there is a danger of electric shock.

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

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2019 - 09/2022]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL

3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click here 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV [01/2019 - 09/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): REMOVAL+

4. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV [01/2019 - 09/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): REMOVAL+

5. DISCONNECT ENGINE WIRE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

6. REMOVE AUXILIARY BATTERY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; MAINTENANCE: 2ZR-FXE AUXILIARY BATTERY: REMOVAL

7. REMOVE SERVICE PLUG GRIP

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

8. DRAIN ENGINE COOLANT (for Engine)

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; MAINTENANCE: 2ZR-FXE COOLANT (for Engine Coolant): REPLACEMENT+

9. REMOVE ECM

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

10. REMOVE BATTERY CLAMP SUB-ASSEMBLY

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

11. SEPARATE FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

12. DISCONNECT ENGINE WIRE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

13. REMOVE CONNECTOR COVER ASSEMBLY

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

14. CHECK TERMINAL VOLTAGE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

15. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

16. DISCONNECT HV FLOOR UNDER WIRE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

17. DISCONNECT HV AIR CONDITIONING WIRE

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

18. SEPARATE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Wear insulated gloves.

(a) Remove the 5 bolts and 2 nuts and separate the inverter with converter assembly.

NOTICE:

  • To prevent damage due to static electricity, do not touch the terminals of the inverter with converter assembly connector.
  • Make sure to seal the inverter with converter assembly with the connector cover assembly or tape (non-residue type) etc., to prevent entry of foreign matter and water.

(b) Using a rope or equivalent, secure the inverter with converter assembly with the hood hinge.

NOTICE:

  • Be careful not to damage the surrounding components when securing the inverter with converter assembly.
  • To prevent damage to the inverter with converter assembly, do not hold the coolant pipe, bracket or connector when securing the inverter with converter assembly.
  • To prevent damage due to static electricity, do not touch the terminals of the inverter with converter assembly connector.
  • Make sure to seal the inverter with converter assembly with the connector cover assembly or tape (non-residue type) etc., to prevent entry of foreign matter and water.

*a

Rope

19. REMOVE EGR PIPE ASSEMBLY

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

20. REMOVE EGR VALVE ASSEMBLY

(a) Disconnect the EGR valve assembly connector.

(b) Slide the clip and disconnect the No. 6 water by-pass hose from the EGR valve assembly.

(c) Slide the clip and disconnect the water by-pass hose from the EGR valve assembly.

(d) Remove the 3 nuts.

(e) Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.

(f) Remove the EGR valve assembly from the EGR pipe with cooler sub-assembly.

(g) Remove the EGR valve gasket from the EGR valve assembly.