| Last Modified: 05-13-2024 | 6.11:8.1.0 | Doc ID: RM1000000028TG8 |
| Model Year Start: 2023 | Model: GR Corolla | Prod Date Range: [11/2022 - ] |
| Title: G16E-GTS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2023 - 2025 MY GR Corolla [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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![2019 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2018 - ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION](/t3Portal/stylegraphics/info.gif)
HINT:
Perform "Inspection After Repair" after replacing the engine assembly.
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PROCEDURE
1. INSTALL ENGINE HANGER
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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 PROPELLER SHAFT HEAT INSULATOR
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8. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
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9. INSTALL ENGINE WIRE
(a) Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.
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(b) Install the 2 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} |
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(c) 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} |
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(d) Install the 4 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} |
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10. INSTALL GENERATOR ASSEMBLY
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11. 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}
12. INSTALL FAN AND GENERATOR V BELT
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13. INSTALL FLYWHEEL HOUSING UNDER COVER
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(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. |
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14. INSTALL STARTER ASSEMBLY
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15. INSTALL FLYWHEEL HOUSING SIDE COVER
(a) Install the flywheel housing side cover to the cylinder block sub-assembly.
16. 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).
17. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
HINT:
Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.
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(a) Temporarily install the engine mounting insulator sub-assembly RH to the vehicle. |
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(b) Install the 2 bolts and nut in the order shown in the illustration.
Torque:
72 N·m {734 kgf·cm, 53 ft·lbf}
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(c) Connect the air conditioner tube with the clamp. |
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18. 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.
19. INSTALL ENGINE MOUNTING INSULATOR LH
HINT:
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
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(a) Temporarily install the engine mounting insulator LH to the vehicle. |
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(b) Install the 4 bolts and nut in the order shown in the illustration.
Torque:
42 N·m {428 kgf·cm, 31 ft·lbf}
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(c) Engage the clamp. |
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20. REMOVE ENGINE HANGERS
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21. 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.
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(c) Connect the front suspension crossmember sub-assembly to the vehicle with the 4 bolts. Torque: 141 N·m {1438 kgf·cm, 104 ft·lbf} |
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(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} |
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(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} |
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22. CONNECT NO. 1 CLUTCH HOSE
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(a) Connect the No. 1 clutch hose to the clutch flexible hose bracket with a new clip. |
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(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.
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- 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)
23. 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}
24. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH
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(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} |
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25. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH
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(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} |
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26. FRONT DRIVE SHAFT ASSEMBLY DRIVE SHAFT ASSEMBLY
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27. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
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28. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
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29. INSTALL COLUMN HOLE COVER SILENCER SHEET
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30. CONNECT DISCHARGE HOSE SUB-ASSEMBLY
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31. CONNECT SUCTION HOSE SUB-ASSEMBLY
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32. CONNECT FUEL TUBE SUB-ASSEMBLY
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(a) Connect the fuel tube sub-assembly to the fuel pipe. Click here
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(b) Install the No. 1 fuel pipe clamp to the fuel tube sub-assembly. |
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33. 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.
34. CONNECT NO. 3 WATER BY-PASS HOSE ASSEMBLY
(a) Connect the No. 3 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
35. CONNECT NO. 1 FUEL VAPOR FEED HOSE
(a) Connect the No. 1 fuel vapor feed hose to the fuel tank to canister tube.
36. 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.
37. 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.
38. CONNECT CHECK VALVE UNION TO CONNECTOR TUBE HOSE
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39. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
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(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. |
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(b) Connect the transmission control cable assembly to the manual transaxle assembly with the 2 clips (A).
40. INSTALL ECM
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41. INSTALL NO. 2 AIR TUBE
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(a) Install the No. 2 air tube with the bolt. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf} |
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(b) Tighten the 2 hose clamps.
Torque:
6.0 N·m {61 kgf·cm, 53 in·lbf}
42. 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.
43. CONNECT NO. 1 RADIATOR HOSE
(a) Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
44. 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}
(c) Connect the 3 connectors to the engine room relay block.
(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}
45. INSTALL COVER RELAY BLOCK UPR
(a) Install the junktion block cover.
46. INSTALL NO. 1 RELAY BLOCK COVER
(a) Install the No. 1 relay block cover.
47. 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 to the air cleaner bracket.
48. INSTALL AIR CLEANER WITH AIR CLEANER HOSE
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49. INSTALL NO. 1 AIR CLEANER INLET
50. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
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(a) Engage the 4 clamps to install the No. 1 engine cover sub-assembly. NOTICE:
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51. INSTALL RADIATOR SUPPORT OPENING COVER
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52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
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53. INSTALL SPARE WHEEL CUSHION
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54. INSTALL DECK BOARD ASSEMBLY
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55. BLEED CLUTCH LINE
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56. ADD ENGINE OIL
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57. ADD ENGINE COOLANT
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58. ADD MANUAL TRANSAXLE OIL
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59. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT
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60. WARM UP ENGINE
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61. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY
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62. INSPECT FOR ENGINE OIL LEAK
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63. INSPECT MANUAL TRANSAXLE OIL LEAK
64. INSPECT FOR COOLANT LEAK
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65. INSPECT FOR REFRIGERANT LEAK
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66. INSPECT FOR FUEL LEAK
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67. INSPECT FOR EXHAUST GAS LEAK
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68. CHECK ENGINE OIL LEVEL
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69. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL
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70. INSTALL REAR ENGINE UNDER COVER LH
(a) w/o Engine Under Cover Air Guide:
(1) Install the rear engine under cover LH to the vehicle with the screw and 5 clips.
(b) w/ Engine Under Cover Air Guide:
(1) Install the rear engine under cover LH to the vehicle with the screw and 4 clips.
71. INSTALL REAR ENGINE UNDER COVER RH
(a) w/o Engine Under Cover Air Guide:
(1) Install the rear engine under cover RH to the vehicle with the screw and 5 clips.
(b) w/ Engine Under Cover Air Guide:
(1) Install the rear engine under cover RH to the vehicle with the screw and 4 clips.
72. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY
(a) Install the No. 1 engine under cover assembly to the vehicle with the 4 bolts and 9 clips.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
73. INSTALL NO. 3 ENGINE UNDER COVER AIR GUIDE (w/ Engine Under Cover Air Guide)
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(a) Install the No. 3 engine under cover air guide with the bolt and 2 screws. NOTICE: Temporary tighten the 2 screws in the order of (A) and (B) and then fully tighten the 2 screws and bolt in the order of (C), (B) and (A). |
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74. INSTALL NO. 2 ENGINE UNDER COVER AIR GUIDE (w/ Engine Under Cover Air Guide)
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(a) Install the No. 2 engine under cover air guide with the 2 screws. NOTICE: Temporarily tighten the screw (A), and then fully tighten the 2 screws in the order of (B) and (A). |
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75. INSTALL WINDSHIELD WASHER JAR ASSEMBLY (w/ Engine Under Cover Air Guide)
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(a) Install the 3 bolts. Torque: 5.5 N·m {56 kgf·cm, 49 in·lbf} |
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(b) Install the windshield washer jar assembly with screw.
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(c) Engage the 2 clamps. |
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(d) Connect the connector.
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(e) Engage the clamp and 3 guides. |
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(f) Connect the connector.
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(g) Connect the washer hose. |
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76. INSTALL INLET HOSE (w/ Engine Under Cover Air Guide)
(a) Install the inlet hose as shown in the illustration.
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Install in this Direction |
(b) Install the clip.
77. INSTALL FRONT BUMPER ASSEMBLY (w/ Engine Under Cover Air Guide)
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78. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (w/ Engine Under Cover Air Guide)
(a) Install the 2 grommets.
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Install in this Direction |
(b) Engage the claw as shown in the illustration.
(c) Install the front fender splash shield sub-assembly LH with the 11 clips and 9 screws.
79. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (w/ Engine Under Cover Air Guide)
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80. ADD WASHER FLUID (w/ Engine Under Cover Air Guide)
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81. INSTALL FRONT WHEELS
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82. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
83. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
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84. PERFORM INITIALIZATION
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85. INSPECT IGNITION TIMING
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86. INSPECT ENGINE IDLE SPEED
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87. INSPECT CO/HC
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88. CHECK SPEED SENSOR SIGNAL
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