M20A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2023 - 2025 MY Corolla Corolla Hatchback [03/2023

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM100000002BA1F
Model Year Start: 2023	Model: Corolla Hatchback	Prod Date Range: [03/2023 - ]
Title: M20A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2023 - 2025 MY Corolla Corolla Hatchback [03/2023 - ]

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 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
1: w/ Steering Lock Function 2: w/o Smart Key System 3: w/ Smart Key System 4: If matchmarks were not placed when removing parts related to steering operation, perform end position initial setting. 5: If transaxle compensation code read from ECM 6: If transaxle compensation code not read from ECM
Replacement of ECM	Vehicle Identification Number (VIN) registration	MIL comes on
	for K121 ECU configuration	-
	Update ECU security key	Vehicle Control History (RoB) are stored
	ECU communication ID registration (Immobiliser system)	Engine start function
Replacement of ECM*3	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 ECM*2	Code registration (Immobiliser system)	Engine start Telematics System
Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Replacement of continuously variable transaxle assembly	for K120 Input transaxle compensation code into TCM Perform reset memory CVT oil pressure calibration Perform road test to allow TCM to learn	Large shift shock Deterioration of fuel efficiency	Initialization: Registration:
Replacement of continuously variable transaxle assembly	for K121 Input transaxle compensation code into ECM Perform reset memory CVT oil pressure calibration Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	Initialization: Registration:
Replacement of ECM	for K120 Perform reset memory CVT oil pressure calibration Perform road test to allow TCM to learn	Large shift shock Deterioration of fuel efficiency	Initialization: Registration:
Replacement of ECM	for K121 Transfer transaxle compensation code5 Reset transaxle compensation code6 CVT oil pressure calibration Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	Initialization: Registration:
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	w/ Electric Parking Brake System: w/o Electric Parking Brake System:
CVT fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly	for K120: for K121:
Steering gear assembly4 No. 2 steering intermediate shaft assembly4	for TMC Made End position initial setting	-

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 or the engine assembly with transaxle may fall off the engine lifter.

*a	An Object Exceeding Weight Limit of Engine Lifter

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

HINT:

When the cable is disconnected / reconnected to the 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 Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the vehicle straight ahead at 15 km/h (9 mph) or more for 1 second or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
*1: for Hatchback
Power Door Lock Control System Back door opener*1	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal.

Click here

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here

3. DISCHARGE FUEL SYSTEM PRESSURE

Click here

4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click here

6. REMOVE BATTERY

Click here

7. SECURE STEERING WHEEL

Click here

8. REMOVE FRONT WHEELS

Click here

9. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

(a) Remove the 4 bolts, 10 clips and No. 1 engine under cover assembly from the vehicle.

*A	Type A	*B	Type B
*C	Type C	-	-

10. REMOVE REAR ENGINE UNDER COVER LH

(a) Remove the 3 clips.

(b) Type A:

(1) Remove the screw.

(2) Remove the clip and rear engine under cover LH from the vehicle.

(1) Remove the screw.

(2) Remove the 2 clips and rear engine under cover LH from the vehicle.

11. REMOVE REAR ENGINE UNDER COVER RH

(a) Remove the 3 clips.

(b) Type A:

(1) Remove the screw.

(2) Remove the clip and rear engine under cover RH from the vehicle.

(1) Remove the screw.

(2) Remove the 2 clips and rear engine under cover RH from the vehicle.

12. DRAIN ENGINE OIL

Click here

13. DRAIN ENGINE COOLANT (for Fully Sealed Type)

Click here

14. DRAIN ENGINE COOLANT (for Non-Fully Sealed Type)

Click here

15. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID

Click here

16. REMOVE ECM

Click here

17. DISCONNECT ENGINE WIRE

(a) Remove the 2 bolts to separate the engine wire from the vehicle.

(b) Remove the 3 nuts to separate the engine wire from the positive (+) battery terminal.

18. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Disengage the clamp to separate the engine wire from the battery clamp sub-assembly.

*A	Type A
*B	Type B

(b) Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

19. DISCONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

Click here

20. DISCONNECT NO. 1 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 1 radiator hose from the water outlet.

21. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disengage the clamp to separate the No. 2 radiator hose.

(b) Slide the clip and disconnect the No. 2 radiator hose from the radiator assembly.

22. DISCONNECT WATER INLET HOSE

(a) Slide the clip and disconnect the water inlet hose from the oil cooler assembly.

23. DISCONNECT NO. 2 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 2 water by-pass hose from the oil cooler assembly.

24. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR

Click here

25. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Disengage the clamp to separate the No. 1 fuel vapor feed hose.

(b) Slide the clip and disconnect the No. 1 fuel vapor feed hose from the vacuum surge tank.

26. DISCONNECT INLET HEATER WATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the inlet heater water hose.

*a	Retainer
	Pull out
	Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected flow shutting valve (water valve) and inlet heater water hose connector with plastic bags to prevent damage and contamination.

27. DISCONNECT OUTLET HEATER WATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the outlet heater water hose.

*a	Retainer
	Pull out
	Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector with plastic bags to prevent damage and contamination.

28. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Disengage the clamp to separate the fuel tube sub-assembly.

(b) Disconnect the fuel tube sub-assembly from the fuel pump assembly.

Click here

29. DISCONNECT NO. 4 WATER BY-PASS HOSE

(a) Slide the hose clip and disconnect the No. 4 water by-pass hose from the No. 2 water by-pass pipe assembly.

30. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

Click here

31. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

Click here

32. REMOVE COLUMN HOLE COVER SILENCER SHEET

Click here

33. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

34. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click here

35. REMOVE FRONT FLOOR COVER LH (for Double Wishbone Type Suspension)

Click here

36. REMOVE FRONT FLOOR COVER RH (for Double Wishbone Type Suspension)

Click here

37. REMOVE FRONT FLOOR CENTER BRACE

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

38. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

39. REMOVE DRIVE SHAFT ASSEMBLY

Click here

40. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

Click here

41. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

42. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on an engine lifter.

NOTICE:

Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle and front suspension crossmember sub-assembly level.
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 engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

(b) Type A:

(1) Remove the 2 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

(d) Remove the through bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket LH.

NOTICE:

While holding the nut in place, loosen the through bolt.

(e) Remove the 4 bolts to separate the front suspension crossmember sub-assembly from the vehicle.

(f) Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

NOTICE:

Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

43. REMOVE FUEL DELIVERY GUARD

(a) Remove the bolt and fuel delivery guard from the engine mounting bracket RH.

44. INSTALL ENGINE HANGER

(a) Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

No. 1 Engine Hanger

12281-25030

No. 2 Engine Hanger

12282-25010

Bolt

91552-F1040

90105-A0354

*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger
	Bolt

(b) Attach an engine sling device and hang the engine assembly with transaxle with a chain block.

NOTICE:

Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.

45. REMOVE ENGINE MOUNTING INSULATOR LH

HINT:

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

(a) Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle.

46. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(a) Type A:

(1) Remove the 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle.

(b) Type B:

(1) Remove the 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle.

(1) Remove the bolt, nut and disconnect the air conditioner tube and accessory assembly.

(2) Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle.

(d) Type B:

(1) Remove the bolt, nut and disconnect the air conditioner tube and accessory assembly.

(2) Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle.

47. REMOVE STARTER ASSEMBLY

Click here

48. REMOVE FLYWHEEL HOUSING SIDE COVER

(a) Remove the flywheel housing side cover from the cylinder block sub-assembly.

49. REMOVE ENGINE WIRE

(a) Disconnect all the clamps and connectors and remove the engine wire from the engine assembly with transaxle.

50. REMOVE MANIFOLD STAY

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

51. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

Click here

52. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Disengage the 2 claws and guide to remove the flywheel housing under cover from the cylinder block sub-assembly.

Remove in this Direction

53. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click here

54. REMOVE ENGINE ASSEMBLY

(a) Remove the 8 bolts and engine assembly from the continuously variable transaxle assembly.

NOTICE:

To prevent damage to the 2 knock pins, do not pry between the continuously variable transaxle assembly and engine assembly.

HINT:

Bolt (A), (B): Remove from continuously variable transaxle assembly side.
Bolt (C): Remove from engine assembly side.

55. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

56. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Click here

57. REMOVE V-RIBBED BELT

Click here

58. REMOVE GENERATOR ASSEMBLY

for Transaxle CVT with Denso Made Generator:
Click here
for VALEO Made:
Click here

59. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

Click here

60. INSTALL ENGINE TO ENGINE STAND

(a) Install the engine assembly to an engine stand.

61. REMOVE ENGINE HANGER

(a) Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.

REMOVAL

CAUTION / NOTICE / HINT

Necessary Procedures After Parts Removed/Installed/Replaced

for K121

for K120

for K121

for K120

for K121

for TMC Made

Learning completes when vehicle is driven

Learning completes when vehicle is operated normally

PROCEDURE