G16E-GTS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2023 MY GR Corolla [09/2022

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM10000000260TN
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [09/2022 - 11/2022]
Title: G16E-GTS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2023 MY GR Corolla [09/2022 - 11/2022]

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.

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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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 ASSEMBLY FROM ENGINE STAND

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

3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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4. INSTALL FLYWHEEL SUB-ASSEMBLY

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5. INSTALL COVER AND DISC CLUTCH SET

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6. INSTALL MANUAL TRANSAXLE ASSEMBLY

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7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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8. INSTALL PROPELLER SHAFT HEAT INSULATOR

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9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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10. INSTALL ENGINE WIRE

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

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Install the 4 bolts.

Torque:

Bolt (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt (B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

(e) Install the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

11. INSTALL GENERATOR ASSEMBLY

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12. INSTALL TIMING GEAR COVER INSULATOR

(a) Install the timing gear cover insulator to the cylinder block sub-assembly.

13. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

14. INSTALL FAN AND GENERATOR V BELT

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15. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Align the claw of the flywheel housing under cover with the notch of the cylinder block sub-assembly then install.

NOTICE:

Make sure that the orientation is correct when installing.

16. INSTALL STARTER ASSEMBLY

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17. INSTALL FLYWHEEL HOUSING SIDE COVER

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

18. INSTALL NO. 1 FUEL VAPOR FEED HOSE

(a) Engage the 2 clamps.

(b) Install the No. 1 fuel vapor feed hose to the purge valve (purge VSV).

19. 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}

20. INSTALL RESERVE TANK ASSEMBLY

(a) Install the bolt and reserve tank assembly to the vehicle.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(b) Connect the No. 3 water by-pass hose to the reserve tank assembly and slide the clip to secure it.

21. 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	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}

22. REMOVE ENGINE HANGERS

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23. INSTALL ENGINE MOUNTING BRACKET CAP

(a) Install the engine mounting bracket cap to the engine mounting bracket RH.

24. 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 No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 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 sub-assembly RH to the engine mounting bracket RH with the 3 bolts in the order shown illustration.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(e) Install the engine mounting insulator LH to the transaxle assembly with the 4 bolts in the order shown illustration.

Torque:

52 N·m {530 kgf·cm, 38 ft·lbf}

25. CONNECT NO. 1 CLUTCH HOSE

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

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

(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)

26. INSTALL NO. 1 AIR TUBE

(a) Tighten the 2 hose clamps to install the No. 1 air tube.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

27. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

(a) Install the rear side rail reinforcement sub-assembly RH to the front suspension crossmember sub-assembly and vehicle body with the 6 bolts.

Torque:

Bolt (A) :

70 N·m {714 kgf·cm, 52 ft·lbf}

Bolt (B) :

7.0 N·m {71 kgf·cm, 62 in·lbf}

28. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

(a) Install the rear side rail reinforcement sub-assembly LH to the front suspension crossmember sub-assembly and vehicle body with the 4 bolts.

Torque:

70 N·m {714 kgf·cm, 52 ft·lbf}

29. INSTALL DRIVE SHAFT ASSEMBLY

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30. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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31. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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32. INSTALL COLUMN HOLE COVER SILENCER SHEET

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33. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

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34. CONNECT SUCTION HOSE SUB-ASSEMBLY

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35. CONNECT FUEL TUBE SUB-ASSEMBLY

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

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(b) Install the No. 1 fuel pipe clamp to the fuel tube sub-assembly.

36. 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.

37. CONNECT OUTLET HEATER WATER HOSE

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

38. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the fuel tank to canister tube.

39. CONNECT NO. 2 WATER BY-PASS HOSE

(a) Connect the No. 2 water by-pass hose to the No. 4 water by-pass pipe and slide the clip to secure it.

40. CONNECT NO. 1 WATER BY-PASS HOSE

(a) Connect the No. 1 water by-pass hose to the No. 4 water by-pass pipe and slide the clip to secure it.

41. CONNECT UNION TO CONNECTOR TUBE HOSE

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42. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect 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	Clip
*c	Washer

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

43. INSTALL ECM

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44. INSTALL NO. 5 AIR HOSE

(a) Install the a new No. 5 air hose and tighten the hose clamp.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

45. INSTALL NO. 4 AIR HOSE

(a) Install the a new No. 4 air hose to the intercooler tighten the hose clamp.

*a	View A	*b	Paint Mark
*c	3 to 6 mm (0.1181 to 0.2362 in.)	-	-

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

46. INSTALL NO. 2 AIR TUBE

(a) Install the No. 2 air tube with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

*a	Front Side of Vehicle
*b	Upper Side of Vehicle
*c	30° (Tabs of Clip Installation Area)
*d	Paint Mark
*e	2 to 5 mm (0.0787 to 0.1969 in.)

(b) Tighten the 2 hose clamps.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

47. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.

48. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

49. CONNECT ENGINE WIRE

(a) Engage the 2 clamps to connect the engine wire to the vehicle.

(b) Connect the engine wire to the vehicle with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Install the nut.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Install the nut.

Torque:

7.6 N·m {77 kgf·cm, 67 in·lbf}

50. INSTALL COVER RELAY BLOCK UPR

(a) Install the junktion block cover.

51. INSTALL NO. 1 RELAY BLOCK COVER

(a) Install the No. 1 relay block cover.

52. INSTALL AIR CLEANER BRACKET

(a) Install the air cleaner bracket with the 2 bolts.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

(b) Engage the clamp.

53. INSTALL AIR CLEANER WITH AIR CLEANER HOSE

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54. INSTALL NO. 1 AIR CLEANER INLET

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55. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Engage the 4 clamps to install the No. 1 engine cover sub-assembly.

NOTICE:

Securely engage the clamps.
If the clamps are forcibly engaged or struck with an object, they may be damaged.

56. INSTALL RADIATOR SUPPORT OPENING COVER

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57. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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58. INSTALL SPARE WHEEL CUSHION

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59. INSTALL DECK BOARD ASSEMBLY

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60. BLEED CLUTCH LINE

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61. ADD ENGINE OIL

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62. ADD ENGINE COOLANT

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63. ADD MANUAL TRANSAXLE OIL

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64. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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65. WARM UP ENGINE

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66. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY

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67. INSPECT FOR ENGINE OIL LEAK

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68. INSPECT FOR MANUAL TRANSAXLE OIL LEAK

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69. INSPECT FOR COOLANT LEAK

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70. INSPECT FOR REFRIGERANT LEAK

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71. INSPECT FOR FUEL LEAK

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72. INSPECT FOR EXHAUST GAS LEAK

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73. CHECK ENGINE OIL LEVEL

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74. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL

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75. INSTALL REAR ENGINE UNDER COVER LH

(a) Install the rear engine under cover LH to the vehicle with the screw and 5 clips.

76. INSTALL REAR ENGINE UNDER COVER RH

(a) Install the rear engine under cover RH to the vehicle with the screw and 5 clips.

77. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

(a) Install the No. 1 engine under cover assembly to the vehicle with the 4 bolts and 10 clips.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

78. INSTALL FRONT WHEELS

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79. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

80. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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81. PERFORM INITIALIZATION

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82. INSPECT IGNITION TIMING

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83. INSPECT ENGINE IDLE SPEED

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84. INSPECT CO/HC

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85. CHECK SPEED SENSOR SIGNAL

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