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

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000002BA1G
Model Year Start: 2023	Model: Corolla Hatchback	Prod Date Range: [03/2023 - ]
Title: M20A-FKS (ENGINE MECHANICAL): ENGINE UNIT: 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 unit 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 Replacement of throttle body with motor assembly Replacement of cam timing control motor with EDU assembly Removal and installation of a cam timing control motor with EDU assembly Replacement of camshaft timing gear assembly Removal and installation of a camshaft timing gear assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing exhaust gear assembly Replacement of port fuel injector assembly Replacement of direct fuel injector assembly Replacement of fuel pump assembly (for high pressure side) Replacement of engine coolant temperature sensor Replacement of spark plug Replacement of ignition coil assembly Replacement of EGR valve assembly Replacement of knock control sensor Replacement of air fuel ratio sensor (sensor 2)	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	-

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 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. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE:

Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

(a) Remove the 2 bolts and V-ribbed belt tensioner assembly from the No. 2 timing chain cover assembly.

2. DISCONNECT NO. 2 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

3. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

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

(b) Remove the bolt and No. 2 water by-pass pipe sub-assembly from the water hose clamp bracket.

4. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(a) Remove the bolt to disconnect the flow shutting valve (water by-pass hose assembly) from the water hose clamp bracket.

(b) Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.

HINT:

Use a container to catch any engine coolant which flows out of the flow shutting valve (water by-pass hose assembly) and water by-pass outlet sub-assembly.

5. REMOVE WATER HOSE CLAMP BRACKET

(a) Remove the bolt and water hose clamp bracket from the water hose clamp bracket.

(b) Remove the 2 bolts and water hose clamp bracket from the camshaft housing sub-assembly.

6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

7. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

9. REMOVE THROTTLE BODY GASKET

Click here

10. REMOVE EGR COOLER ASSEMBLY

Click here

11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here

12. REMOVE EGR VALVE ASSEMBLY

Click here

13. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.

(b) Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.

14. REMOVE INTAKE MANIFOLD STAY

Click here

15. REMOVE INTAKE MANIFOLD

Click here

16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here

17. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

Click here

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

Click here

18. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using an 8 mm socket wrench, remove the bolt.

(b) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

19. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

20. REMOVE NO. 1 WATER BY-PASS HOSE ASSEMBLY

(a) Slide the clip and remove the plug from the No. 1 water by-pass hose assembly.

(b) Remove the bolt.

(c) Slide the 2 clips and remove the No. 1 water by-pass hose assembly from the water inlet with thermostat sub-assembly and cylinder head sub-assembly.

21. REMOVE SENSOR WIRE

(a) Disconnect the 3 connectors.

(b) Disengage the 3 clamps.

22. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 2 clamps.

23. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here

24. REMOVE FUEL DELIVERY SPACER

Click here

25. REMOVE INJECTOR VIBRATION INSULATOR

Click here

26. REMOVE NO. 5 ENGINE WIRE

Click here

27. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here

28. REMOVE FUEL DELIVERY PIPE

Click here

29. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here

30. REMOVE FUEL INJECTOR SEAL

Click here

31. REMOVE IGNITION COIL ASSEMBLY

Click here

32. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the engine oil level dipstick.

(b) Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the cylinder head sub-assembly.

33. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

Click here

34. REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

(a) Remove the 4 bolts, engine water pump assembly (water inlet housing) and gasket from the cylinder block sub-assembly.

35. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 2 bolts and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.

36. REMOVE PURGE VALVE (PURGE VSV)

w/ Canister Pump Module:
Click here
w/o Canister Pump Module:
Click here

37. REMOVE VACUUM SURGE TANK

(a) Remove the bolt and vacuum surge tank from the vacuum surge tank bracket.

38. REMOVE VACUUM SURGE TANK BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and vacuum surge tank bracket from the camshaft housing sub-assembly.

39. REMOVE NO. 2 VENTILATION HOSE

(a) Slide the clip and remove the No. 2 ventilation hose from the cylinder head cover sub-assembly.

40. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.

(b) Using an 8 mm socket wrench, remove the bolt and wire harness clamp bracket from the camshaft housing sub-assembly.

41. REMOVE STUD BOLT

(a) Using an E8 "TORX" socket wrench, remove the stud bolt from the timing chain cover assembly.

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