Last Modified: 07-31-2024 6.11:8.1.0 Doc ID: RM10000000260TR
Model Year Start: 2023 Model: GR Corolla Prod Date Range: [09/2022 -           ]
Title: G16E-GTS (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY; 2023 - 2025 MY GR Corolla [09/2022 -        ]

DISASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

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 2019 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. REMOVE SPARK PLUG

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; MAINTENANCE: G16E-GTS SPARK PLUG: REMOVAL+

2. REMOVE OIL PRESSURE AND TEMPERATURE SENSOR

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (LUBRICATION): OIL PRESSURE AND TEMPERATURE SENSOR: REMOVAL+

3. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): CAMSHAFT POSITION SENSOR: REMOVAL+

4. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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5. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side)

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): CAMSHAFT OIL CONTROL SOLENOID: REMOVAL+

6. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side)

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): CAMSHAFT OIL CONTROL SOLENOID: REMOVAL+

7. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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8. REMOVE WATER INLET WITH WATER PUMP HOUSING SUB-ASSEMBLY

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9. REMOVE OIL FILLER CAP ASSEMBLY

(a) Remove the oil filler cap assembly from the cylinder head cover sub-assembly.

10. REMOVE OIL FILLER CAP GASKET

(a) Remove the oil filler cap gasket from the oil filler cap assembly.

11. REMOVE CRANKSHAFT POSITION SENSOR

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12. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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13. REMOVE VACUUM PUMP ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; BRAKE SYSTEM (OTHER): VACUUM PUMP (for G16E-GTS): REMOVAL+

14. REMOVE CRANKSHAFT PULLEY ASSEMBLY

(a) Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set bolt until 2 or 3 threads remain screwed into the crankshaft.

SST: 09213-54015

SST: 09330-00021

*a

Hold

*b

Turn

(b) Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley assembly and crankshaft pulley set bolt.

SST: 09950-50013

09951-05010

09952-05010

09953-05020

09954-05070

09957-04010

HINT:

Apply lubricant to the threads and end of SST.

*1

Crankshaft Pulley Set Bolt

*a

Hold

*b

Turn

15. REMOVE OUTLET WATER SUB-ASSEMBLY

(a) Remove the 2 nuts, outlet water sub-assembly and outlet water gasket from the cylinder head sub-assembly.

16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 17 bolts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

(b) Remove the 5 cylinder head cover gaskets from the cylinder head cover sub-assembly.

(c) Remove the 2 camshaft bearing cap oil hole gaskets from the No. 1 camshaft bearing cap and fuel pump lifter housing.

17. REMOVE SPARK PLUG TUBE GASKET

(a) Using a screwdriver, pry out the 3 spark plug tube gaskets from the cylinder head cover sub-assembly.

NOTICE:

Be careful not to damage the cylinder head cover sub-assembly.

HINT:

Tape the screwdriver tip before use.

*a

Protective Tape

18. REMOVE NO. 1 VACUUM PUMP BRACKET

(a) Remove the 2 bolts and No. 1 vacuum pump bracket from the cylinder head sub-assembly.

19. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 3 bolts and engine mounting bracket RH from the No. 2 timing chain cover assembly.

20. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY

(a) Remove the 8 bolts.

(b) Remove the No. 2 timing chain cover assembly from the cylinder head sub-assembly by prying the No. 2 timing chain cover assembly with a screwdriver with its tip wrapped with protective tape.

21. REMOVE TIMING CHAIN COVER OIL SEAL

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22. REMOVE TIMING CHAIN COVER ASSEMBLY

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23. SET VALVE TIMING

(a) Temporarily install the crankshaft pulley bolt.

(b) Rotate the crankshaft clockwise and make sure that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly is at the top.

*a

Timing Mark

(c) Check that the crankshaft timing gear key as shown in the illustration.

*1

Crankshaft Timing Gear Key

*a

Approximately 27°

(d) Remove the crankshaft pulley bolt.

HINT:

As the exhaust camshaft sub-assembly may rotate counterclockwise strongly when the crankshaft pulley set bolt is removed, use a wrench to hold the hexagonal portion of the exhaust camshaft sub-assembly.

24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the stopper plate of the No. 1 chain tensioner assembly clockwise to release the lock and push in the plunger.

*1

Stopper Plate

*2

Plunger

(b) Turn the stopper plate counterclockwise to set the lock.

(c) Insert a pin into the stopper plate hole.

(d) Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder block sub-assembly.

(e) Remove the chain tensioner gasket from the No. 1 chain tensioner assembly.

25. REMOVE TIMING CHAIN GUIDE

(a) Remove the 2 nut and timing chain guide from the damper plate spacer.

26. REMOVE DAMPER PLATE SPACER

(a) Remove the damper plate spacers from the No. 2 camshaft bearing cap.

27. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and chain tensioner slipper from the cylinder head sub-assembly.

28. REMOVE CHAIN SUB-ASSEMBLY

(a) Remove the chain sub-assembly.

29. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 1 chain vibration damper.

30. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Remove the crankshaft timing gear or sprocket from the crankshaft.

31. REMOVE CRANKSHAFT TIMING GEAR KEY

(a) Using a screwdriver, remove the 2 crankshaft timing gear keys from the crankshaft.

HINT:

Tape the screwdriver tip before use.

*a

Protective Tape

32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.

NOTICE:

Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

(b) Using a 5 mm hexagon socket wrench, remove the 3 bolts.

(c) Remove the camshaft timing exhaust gear assembly and camshaft timing valve assembly from the exhaust camshaft sub-assembly.

*1

Camshaft Timing Exhaust Gear Assembly

*2

Camshaft Timing Valve Assembly

33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.

NOTICE:

Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

(b) Using a 5 mm hexagon socket wrench, remove the 3 bolts.

(c) Remove the camshaft timing gear assembly and camshaft timing valve assembly from the intake camshaft sub-assembly.

*1

Camshaft Timing Gear Assembly

*2

Camshaft Timing Valve Assembly

34. REMOVE FUEL PUMP LIFTER GUIDE

(a) Remove the 2 bolts and fuel pump lifter guide from the fuel pump lifter housing.

35. REMOVE FUEL PUMP LIFTER HOUSING

(a) Remove the 3 bolts and fuel pump lifter housing from the cylinder head sub-assembly.

36. REMOVE CAMSHAFT POSITION SENSOR HOLDER

(a) Remove the bolt and camshaft position sensor holder from the cylinder head sub-assembly.

37. REMOVE CAMSHAFT BEARING CAP

(a) Remove the 18 bolts.

*1

No. 2 Camshaft Bearing Cap

*2

No. 4 Camshaft Bearing Cap

*3

No. 6 Camshaft Bearing Cap

(b) Remove the No. 2 camshaft bearing cap, 6 No. 4 camshaft bearing caps and No. 6 camshaft bearing cap from the No. 1 camshaft bearing cap, camshaft bearing cap and No. 5 camshaft bearing cap.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

38. REMOVE EXHAUST CAMSHAFT SUB-ASSEMBLY

(a) Remove the exhaust camshaft sub-assembly from the cylinder head sub-assembly.

39. REMOVE INTAKE CAMSHAFT SUB-ASSEMBLY

(a) Remove the intake camshaft sub-assembly from the cylinder head sub-assembly.

40. REMOVE NO. 1 CAMSHAFT BEARING CAP

(a) Remove the No. 1 camshaft bearing cap from the cylinder head sub-assembly.

41. REMOVE NO. 5 CAMSHAFT BEARING CAP

(a) Remove the No. 5 camshaft bearing cap from the cylinder head sub-assembly.

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

(a) Remove the 12 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

43. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 12 valve lash adjuster assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

44. REMOVE VALVE STEM CAP

(a) Remove the 12 valve stem caps from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

45. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Using a 12 mm socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 plate washers.

NOTICE:

  • Be careful not to drop the plate washers into the cylinder head sub-assembly.
  • Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(b) Remove the 3 bolts and cylinder head sub-assembly from the cylinder block sub-assembly.

46. REMOVE CYLINDER HEAD GASKET

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47. REMOVE OIL FILTER SUB-ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; MAINTENANCE: G16E-GTS OIL AND OIL FILTER: REPLACEMENT+

48. REMOVE OIL FILTER UNION

(a) Using a 12 mm hexagon socket wrench, remove the oil filter union from the oil filter bracket sub-assembly.

49. REMOVE OIL COOLER ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (LUBRICATION): ENGINE OIL COOLER: REMOVAL+

50. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

(a) Remove the 3 bolts and oil filter bracket sub-assembly from the cylinder block sub-assembly.

(b) Remove the 2 gaskets.

51. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and oil pan drain gasket from the No. 2 oil pan sub-assembly.

52. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

*a

Nut

(b) Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.

NOTICE:

  • Be careful not to damage the contact surfaces of the No. 2 oil pan sub-assembly and oil pan sub-assembly.
  • Be careful not to damage the oil pan sub-assembly flange.

53. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 13 bolts and oil pan sub-assembly from the crankshaft bearing cap.

54. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 bolts, oil strainer sub-assembly and oil strainer gasket from the crankshaft bearing cap.

55. REMOVE ENGINE BALANCER ASSEMBLY

(a) Remove the 4 bolts and engine balancer assembly from the cylinder block sub-assembly.

56. REMOVE BALANCESHAFT HOUSING SPACER

(a) Remove the 4 balanceshaft housing spacers from the cylinder block sub-assembly.

57. REMOVE REAR ENGINE OIL SEAL

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58. REMOVE STUD BOLT

NOTICE:

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

59. REMOVE RING PIN

NOTICE:

It is not necessary to remove the ring pins unless they are being replaced.