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

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000002KB2Y
Model Year Start: 2023	Model: Corolla Hatchback	Prod Date Range: [03/2023 - ]
Title: M20A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2023 - 2025 MY Corolla Corolla Hatchback [03/2023 - ]

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.

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 FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

3. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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4. INSTALL GENERATOR ASSEMBLY

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

5. INSTALL V-RIBBED BELT

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6. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Click here

7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

8. INSTALL ENGINE ASSEMBLY

(a) Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.

Knock Pin

(b) Install the engine assembly to the continuously variable transaxle assembly with the 8 bolts.

Torque:

Bolt (A) :

64 N·m {653 kgf·cm, 47 ft·lbf}

Bolt (B) :

25 N·m {255 kgf·cm, 18 ft·lbf}

Bolt (C) :

46 N·m {469 kgf·cm, 34 ft·lbf}

Bolt Length:

Bolt	Length
(A)	50 mm (1.97 in.)
(B)	35 mm (1.38 in.)
(C)	45 mm (1.77 in.)

NOTICE:

Make sure that the wire harness or similar items are not pinched between the contact surfaces.
Do not use excess force when installing the continuously variable transaxle assembly.
When mounting the continuously variable transaxle assembly to the engine assembly, make sure to securely fit the knock pins into the knock holes.
Check that the torque converter assembly rotates.
When tightening the bolts, be sure that the mating surfaces of the engine assembly and the continuously variable transaxle assembly are in close contact with one another.

HINT:

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

9. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click here

10. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Engage the 2 claws and guide to install the flywheel housing under cover to the cylinder block sub-assembly.

Install in this Direction

11. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

Click here

12. INSTALL MANIFOLD STAY

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

13. INSTALL ENGINE WIRE

(a) Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.

14. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Install the flywheel housing side cover to the cylinder block sub-assembly.

15. INSTALL STARTER ASSEMBLY

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16. INSTALL 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) Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

(2) Install the 2 bolts and nut in the order shown in the illustration.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

(3) Connect the air conditioner tube and accessory assembly with the bolt and nut.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

(4) Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

Torque:

10.5 N·m {107 kgf·cm, 8 ft·lbf}

(b) Type B:

(1) Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

(2) Install the 2 bolts and nut in the order shown in the illustration.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

(3) Connect the air conditioner tube and accessory assembly with the bolt and nut.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

(4) Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

Torque:

10.5 N·m {107 kgf·cm, 8 ft·lbf}

17. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

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

(a) Temporarily install the engine mounting insulator LH to the vehicle.

(b) Install the 4 bolts and nut in the order shown in the illustration.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 4 bolts and nut in the order of (B), (C), (D), (A) and (E).

18. REMOVE ENGINE HANGER

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19. INSTALL FUEL DELIVERY GUARD

(a) Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

20. 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 oil pan sub-assembly from deforming, do not place any attachments under the 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.

Torque:

141 N·m {1438 kgf·cm, 104 ft·lbf}

(d) Install the engine mounting insulator LH to the engine mounting bracket LH with the through bolt and nut.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

NOTICE:

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

(e) Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

41 N·m {418 kgf·cm, 30 ft·lbf}

21. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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22. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

23. INSTALL DRIVE SHAFT ASSEMBLY

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24. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

25. INSTALL FRONT FLOOR CENTER BRACE

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

26. INSTALL FRONT FLOOR COVER LH (for Double Wishbone Type Suspension)

Click here

27. INSTALL FRONT FLOOR COVER RH (for Double Wishbone Type Suspension)

Click here

28. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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29. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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30. INSTALL COLUMN HOLE COVER SILENCER SHEET

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31. CONNECT SUCTION HOSE SUB-ASSEMBLY

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32. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

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33. CONNECT NO. 2 WATER BY-PASS HOSE

(a) Connect the No. 2 water by-pass hose to the No. 2 water by-pass pipe assembly and slide the hose clip to secure it.

34. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel pump assembly.

Click here

(b) Engage the clamp to connect the fuel tube sub-assembly.

35. CONNECT OUTLET HEATER WATER HOSE

(a) Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater water hose connector and push them together until the outlet heater water hose connector makes a "click" sound.

*a	Protrusion
*b	Cutout

(b) Push in the retainer.

*a	Retainer
	Push
	Push in

(c) Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector are securely connected by pulling on them.

36. CONNECT INLET HEATER WATER HOSE

(a) Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water valve) and push them together until the inlet heater water hose connector makes a "click" sound.

*a	Protrusion
*b	Cutout

(b) Push in the retainer.

*a	Retainer
	Push
	Push in

(c) Check that the flow shutting valve (water valve) and inlet heater water hose connector are securely connected by pulling on them.

37. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the vacuum surge tank and slide the clip to secure it.

(b) Engage the clamp to connect the No. 1 fuel vapor feed hose.

38. CONNECT NO. 1 VACUUM HOSE CONNECTOR

Click here

39. CONNECT NO. 2 WATER BY-PASS HOSE

(a) Connect the No. 2 water by-pass hose to the oil cooler assembly and slide the clip to secure it.

40. CONNECT WATER INLET HOSE

(a) Connect the water inlet hose to the oil cooler assembly and slide the clip to secure it.

41. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

(b) Engage the clamp to connect the No. 2 radiator hose.

42. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

43. CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

NOTICE:

Before connecting the floor shift transmission control select cable, check that the shift lever is in N.

(a) for K120:

(1) Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

NOTICE:

If the transmission control shaft lever is turned counterclockwise more than necessary, manual valve link lever sub-assembly may separate from the manual valve.

*1	Transmission Control Shaft Lever
*a	Manual Valve Link Lever Sub-assembly
*b	Manual Valve

(b) for K121:

(1) Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

(c) Connect the floor shift transmission control select cable to the No. 1 transmission control cable bracket with a new clip.

(d) Connect the floor shift transmission control select cable to the transmission control shaft lever as shown in the illustration.

*a	Correct
*b	Incorrect

44. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly to the vehicle with the 3 bolts.

Torque:

15.4 N·m {157 kgf·cm, 11 ft·lbf}

(b) Engage the clamp to connect the engine wire to the battery clamp sub-assembly.

45. CONNECT ENGINE WIRE

(a) Engage the 3 clamps to connect the engine wire to the vehicle.

(b) Connect the engine wire to the positive (+) battery terminal with the 3 nuts.

Torque:

7.6 N·m {77 kgf·cm, 67 in·lbf}

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

46. INSTALL ECM

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47. INSTALL BATTERY

Click here

48. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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49. ADD ENGINE OIL

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50. ADD ENGINE COOLANT (for Fully Sealed Type)

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51. ADD ENGINE COOLANT (for Non-Fully Sealed Type)

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52. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

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53. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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54. WARM UP ENGINE

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55. INSPECT SHIFT LEVER POSITION

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56. ADJUST SHIFT LEVER POSITION

for TMC Made: Click here

for TMMMS Made: Click here

57. INSPECT FOR ENGINE OIL LEAK

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58. INSPECT FOR COOLANT LEAK (for Fully Sealed Type)

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59. INSPECT FOR COOLANT LEAK (for Non-Fully Sealed Type)

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60. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK

61. INSPECT FOR REFRIGERANT LEAK

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62. INSPECT FOR FUEL LEAK

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63. INSPECT FOR EXHAUST GAS LEAK

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

64. CHECK ENGINE OIL LEVEL

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65. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL (for Fully Sealed Type)

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66. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL (for Non-Fully Sealed Type)

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67. INSTALL REAR ENGINE UNDER COVER LH

(a) Type A:

(1) Install the rear engine under cover LH to the vehicle with the 4 clips.

(2) Install the screw.

(b) Type B:

(1) Install the rear engine under cover LH to the vehicle with the 5 clips.

(2) Install the screw.

68. INSTALL REAR ENGINE UNDER COVER RH

(a) Type A:

(1) Install the rear engine under cover RH to the vehicle with the 4 clips.

(2) Install the screw.

(b) Type B:

(1) Install the rear engine under cover RH to the vehicle with the 5 clips.

(2) Install the screw.

69. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

(a) Install the No. 1 engine under cover assembly to the vehicle with the 4 bolts and 10 clips.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

70. INSTALL FRONT WHEELS

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71. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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72. PERFORM INITIALIZATION

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73. INSPECT IGNITION TIMING

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74. INSPECT ENGINE IDLE SPEED

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75. INSPECT CO/HC

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76. CHECK SPEED SENSOR SIGNAL

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77. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

Click here