G16E-GTS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2023 - 2025 MY GR Corolla [11/2022

Last Modified: 01-27-2025	6.11:8.1.0	Doc ID: RM1000000028LLM
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [11/2022 - 09/2024]
Title: G16E-GTS (ENGINE MECHANICAL): ENGINE UNIT: REMOVAL; 2023 - 2025 MY GR Corolla [11/2022 - 09/2024]

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 unit 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
*1:w/ Steering Lock Function
Replacement of ECM	Perform Vehicle Identification Number (VIN) or frame number registration	MIL illuminates
	ECU configuration	-
	Update ECU security key	Vehicle Control History (RoB) are stored
	Heavy Knock History	-
	ECU communication ID registration (Immobiliser system)	Engine start function
	Code registration (Smart Key System (for Gasoline Model, Start Function))	Wireless Door Lock Control System (for Gasoline Model with Smart Key System) Smart Key System (for Gasoline Model, Entry Function) Smart Key System (for Gasoline Model, Start Function) Steering lock function*1
Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly Replacement of engine assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of camshaft timing exhaust gear assembly Replacement of fuel pump assembly (for high pressure side) Replacement of fuel pressure sensor (for high pressure side) Replacement of air fuel ratio sensor Replacement of engine coolant temperature sensor Replacement of spark plug Replacement of ignition coil assembly Replacement of knock control sensor Replacement of turbocharger sub-assembly Gas leaks from exhaust system is repaired	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Front wheel alignment adjustment	Perform "Reset Memory" Perform "Calibration"	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates
Tire	ECU Data Initialization (When performing tire replacement after RoB code X2104 is output)	Active Torque Split AWD System

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

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven

Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
Front Camera System	Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
Power door lock control system Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

PROCEDURE

1. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

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2. REMOVE FUEL TUBE SUB-ASSEMBLY

(a) Disengage the clamp.

(b) Remove the fuel tube sub-assembly from the fuel pipe sub-assembly.

Click here

3. REMOVE NO. 2 AIR HOSE

(a) Loosen the hose clamp and remove the No. 2 air hose from the turbocharger sub-assembly.

4. REMOVE NO. 6 WATER BY-PASS HOSE

(a) Slide the 2 clips and separate the No. 6 water by-pass hose.

(b) Disengage the clamp and remove the No. 6 water by-pass hose from the No. 1 water hose clamp bracket.

5. REMOVE NO. 5 WATER BY-PASS HOSE

(a) Slide the 2 clips and separate the No. 5 water by-pass hose.

(b) Remove the bolt and No. 5 water by-pass hose from the crankshaft bearing cap.

6. REMOVE NO. 3 VACUUM TRANSMITTING HOSE

(a) Disengage the 2 clamp and remove the No. 3 vacuum transmitting hose.

7. REMOVE NO. 1 TURBO WATER HOSE

(a) Slide the 2 clips and remove the No. 1 turbo water hose.

8. REMOVE NO. 1 WATER BY-PASS PIPE

(a) Slide the clip and separate the No. 1 water by-pass pipe.

(b) Remove the bolt, nut and No. 1 water by-pass pipe.

9. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Remove the bolt and separate the No. 3 water by-pass pipe.

(b) Slide the clip and remove the No. 3 water by-pass pipe.

10. REMOVE NO. 4 WATER BY-PASS PIPE

(a) Remove the 3 bolts and separate the No. 4 water by-pass pipe.

(b) Slide the clip and remove the No. 4 water by-pass pipe.

11. REMOVE WATER BY-PASS HOSE ASSEMBLY

(a) Disengage the clamp.

(b) Slide the 2 clips and remove the water by-pass hose assembly.

12. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)

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13. REMOVE VACUUM SENSOR ASSEMBLY

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14. REMOVE INTAKE AIR PIPE

(a) Separate the No.1 vacuum transmitting hose.

(b) Separate the No. 2 vacuum transmitting hose.

(d) Remove the e3 bolts.

(e) Loosen the hose clamp and remove the intake air pipe from the .

15. REMOVE ENGINE HANGER BRACKET

(a) Remove the 2 bolts and engine hanger bracket from the cylinder head sub-assembly.

16. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket from the cylinder block sub-assembly.

17. REMOVE NO. 4 CYLINDER BLOCK INSULATOR

(a) Remove the 2 bolts and No. 4 cylinder block insulator.

18. REMOVE NO. 1 TURBO INSULATOR

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19. REMOVE TURBOCHARGER SUB-ASSEMBLY

(a) Remove the 2 bolts and separate the outlet turbo oil pipe.

(b) Remove the inlet turbo oil pipe union bolt.

(d) Remove the 7 nuts, collar and turbocharger sub-assembly from the cylinder head sub-assembly.

20. REMOVE EXHAUST MANIFOLD TO HEAD GASKET

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21. REMOVE NO. 2 TURBO INSULATOR

(a) Remove the 2 bolts and No. 2 turbo insulator from the cylinder brock sub-assembly.

22. REMOVE PURGE VALVE (PURGE VSV)

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23. SEPARATE NO. 6 ENGINE WIRE

(a) Disengage the 5 clamps and separate the No. 6 engine wire.

24. REMOVE NO. 2 ENGINE COVER BRACKET

(a) Remove the bolt and No. 2 engine cover bracket from the intake manifold.

25. REMOVE INTAKE MANIFOLD

(a) Remove the 3 bolts and 2 nuts and intake manifold from the cylinder head sub-assembly.

26. REMOVE NO. 1 VENTILATION FLANGE SEPARATOR

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27. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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28. REMOVE WATER BY-PASS PIPE

(a) Remove the bolt and nut.

(b) Slide the clip and remove the water by-pass pipe from the water inlet with thermostat sub-assembly.

29. REMOVE NO. 7 ENGINE WIRE

(a) Disengage the clamp.

(b) Disconnect the connector and remove the No. 7 engine wire.

30. REMOVE FUEL TUBE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp from the fuel tube connector.

(b) Remove the bolt.

Click here

31. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY

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32. REMOVE OIL LEVEL GAGE GUIDE

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33. REMOVE FUEL DELIVERY GUARD

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34. REMOVE NO. 1 DELIVERY PIPE SPACER

(a) Remove the 2 No. 1 delivery pipe spacers.

35. REMOVE FUEL DELIVERY PIPE

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36. REMOVE FUEL DELIVERY SPACER

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37. REMOVE INJECTOR VIBRATION INSULATOR

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38. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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39. REMOVE FUEL PUMP ASSEMBLY

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40. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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41. REMOVE NO. 6 ENGINE WIRE

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42. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

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43. REMOVE FUEL INJECTOR SEAL

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44. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

(a) Remove the No. 2 cylinder block insulator from the cylinder block sub-assembly.

45. REMOVE SENSOR WIRE

(a) Remove the 2 bolts and remove the sensor wire from the cylinder block sub-assembly.

46. REMOVE VENTILATION HOSE

(a) Disengage the clamp.

(b) Slide the clip and remove the ventilation hose from the cylinder head cover sub-assembly.

47. REMOVE VACUUM REGULATING VALVE ASSEMBLY

(a) Remove the 2 bolts and vacuum regulating valve assembly from the cylinder head cover sub-assembly.

48. REMOVE IGNITION COIL ASSEMBLY

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49. REMOVE ENGINE COVER JOINT

(a) Remove the 2 engine cover joints from the cylinder head cover sub-assembly.

50. REMOVE ENGINE COVER BRACKET

(a) Remove the bolt and engine cover bracket from the No. 1 vacuum pump bracket.

51. REMOVE FUEL HOSE BRACKET

(a) Remove the 2 bolts and fuel hose bracket form the cylinder head cover sub-assembly.

52. REMOVE INTAKE PIPE OR HOSE STAY

(a) Remove the 3 bolts and intake pipe or hose stay from the cylinder head cover sub-assembly.

53. REMOVE NO. 3 CYLINDER BLOCK INSULATOR

(a) Remove the No. 3 cylinder block insulator from the cylinder block sub-assembly.