Toyota Corolla Cross: Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed, installed, or replaced during the 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
Replacement of engine assembly Gas leaks from exhaust system is repaired	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Replacement of inverter with converter assembly	Resolver learning	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver
Front wheel alignment adjustment	Perform "Calibration"	DTCs are stored ABS warning light illuminates Brake system warning light (yellow indicator) illuminates Slip indicator light illuminates Electronically controlled brake system does not operate correctly
Suspension, tires, etc.	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Initialize headlight ECU subassembly LH	Automatic headlight beam level control system

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 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 15 km/h (10 mph) or more for 1 second 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.
  Power back door system	Fully close the back door by hand. HINT: Initialization is not necessary if the above procedures are performed while the back door is closed.
  Air conditioning system	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	PRECAUTION	-		-	-
2	RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM	-	-		-
3	DISCHARGE FUEL SYSTEM PRESSURE	-		-	-
4	ALIGN FRONT WHEELS FACING STRAIGHT AHEAD	-		-	-
5	DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
6	FRONT WHEELS	-		-	-
7	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
8	REAR ENGINE UNDER COVER LH	51444A	-	-	-
9	REAR ENGINE UNDER COVER RH	51443C	-	-	-
10	FRONT BUMPER ASSEMBLY	-	-	-	-
11	DRAIN ENGINE OIL	-	-		-
12	DRAIN ENGINE COOLANT	-	-		-
13	DRAIN HYBRID TRANSAXLE FLUID	-	-		-

Procedure		Part Name Code
14	INLET NO. 1 AIR CLEANER	17751	-	-	-
15	INVERTER WITH CONVERTER ASSEMBLY	G92A0	-	-	-
16	NO. 1 RELAY BLOCK COVER	82662A	-	-	-
17	DISCONNECT ENGINE WIRE	-	-	-	-
18	INVERTER RESERVE TANK ASSEMBLY	G92A0A	-	-	-
19	TRANSMISSION CONTROL CABLE ASSEMBLY	33820B	-	-	-
20	NO. 1 RADIATOR HOSE	16571C	-	-	-
21	NO. 2 RADIATOR HOSE	16572D	-	-	-
22	INLET HYBRID RADIATOR HOSE	G922H	-	-	-
23	OUTLET NO. 1 HYBRID WATER PUMP HOSE	G922C	-	-	-
24	NO. 3 FUEL VAPOR FEED HOSE	23827F	-	-	-
25	FUEL VAPOR FEED HOSE NO. 2	23827A	-	-	-
26	FUEL VAPOR FEED HOSE NO. 1	23826	-	-	-
27	PURGE VALVE (PURGE VSV)	25860	-	-	-
28	INLET HEATER WATER HOSE	-		-	-
29	OUTLET HEATER WATER HOSE	-		-	-
30	FUEL TUBE SUB-ASSEMBLY	23901		-	-
31	WATER BY-PASS HOSE	16283B	-	-	-
32	DISCHARGE HOSE SUB-ASSEMBLY	88703		-	-
33	SUCTION HOSE SUB-ASSEMBLY	88704		-	-

●

Non-reusable part

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Procedure		Part Name Code
34	SECURE STEERING WHEEL	-		-	-
35	COLUMN HOLE COVER SILENCER SHEET	45259A	-	-	-
36	NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY	45260		-	-
37	NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY	45025D		-	-
38	FRONT EXHAUST PIPE ASSEMBLY	17410	-	-	-
39	DRIVE SHAFT ASSEMBLY	-	-	-	-

Procedure		Part Name Code
40	FRONT BUMPER LOWER ABSORBER	52618	-	-	-
41	NO. 2 FRONT BUMPER REINFORCEMENT	52132A	-	-	-
42	FRONT BUMPER BAR REINFORCEMENT LH	52134C	-	-	-
43	FRONT BUMPER BAR REINFORCEMENT RH	52133C	-	-	-

Procedure		Part Name Code
44	ENGINE ASSEMBLY WITH TRANSAXLE	-		-	-
45	EMISSION CONTROL VALVE BRACKET	-	-	-	-
46	WIRE HARNESS CLAMP BRACKET	-		-	-
47	ENGINE HANGERS	-		-	-
48	ENGINE MOUNTING INSULATOR LH	12372A		-	-
49	ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH	12305		-	-
50	STARTER HOLE INSULATOR	28193	-	-	-
51	FLYWHEEL HOUSING SIDE COVER	11363A		-	-
52	HV AIR CONDITIONING WIRE	821H2		-	-

*1	ENGINE MOUNTING BRACKET CAP
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

Procedure		Part Name Code
53	REMOVE ENGINE WIRE	82121	-	-	-
54	MANIFOLD STAY	17118		-	-
55	ENGINE ASSEMBLY	-		-	-
56	COMPRESSOR WITH MOTOR ASSEMBLY	88370		-	-
57	TRANSMISSION INPUT DAMPER ASSEMBLY	31270		-	-
58	FLYWHEEL SUB-ASSEMBLY	13405		-	-
59	NO. 1 CRANKSHAFT POSITION SENSOR PLATE	19315	-	-	-
60	ENGINE TO ENGINE STAND	-		-	-
61	REMOVE ENGINE HANGERS	-	-	-	-

PROCEDURE

1. PRECAUTION

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2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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3. DISCHARGE FUEL SYSTEM PRESSURE

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4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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6. REMOVE FRONT WHEELS

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7. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

8. REMOVE REAR ENGINE UNDER COVER LH

9. REMOVE REAR ENGINE UNDER COVER RH

10. REMOVE FRONT BUMPER ASSEMBLY

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11. DRAIN ENGINE OIL

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12. DRAIN ENGINE COOLANT (for Engine)

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13. DRAIN HYBRID TRANSAXLE FLUID

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14. REMOVE INLET NO. 1 AIR CLEANER

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15. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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16. REMOVE NO. 1 RELAY BLOCK COVER

17. DISCONNECT ENGINE WIRE

18. DISCONNECT INVERTER RESERVE TANK ASSEMBLY

19. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

20. DISCONNECT NO. 1 RADIATOR HOSE

21. DISCONNECT NO. 2 RADIATOR HOSE

22. DISCONNECT INLET HYBRID RADIATOR HOSE

23. DISCONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE

24. REMOVE NO. 3 FUEL VAPOR FEED HOSE

25. REMOVE FUEL VAPOR FEED HOSE NO. 2

26. REMOVE FUEL VAPOR FEED HOSE NO. 1

27. REMOVE PURGE VALVE (PURGE VSV)

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28. DISCONNECT INLET HEATER WATER HOSE

*a	Retainer	-	-
	Pull out		Pull off

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

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

(3) Cover the disconnected water hose sub-assembly and inlet heater water hose connector with plastic bags to prevent damage and contamination.

29. DISCONNECT OUTLET HEATER WATER HOSE

*a	Retainer	-	-
	Pull out		Pull off

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

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

(3) Cover the disconnected water hose sub-assembly and outlet heater water hose connector with plastic bags to prevent damage and contamination.

30. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(1) Disengage the claw and remove the No. 1 fuel pipe clamp as shown in the illustration.

(2) Disconnect the fuel tube sub-assembly from the fuel pipe.

HINT:

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31. DISCONNECT WATER BY-PASS HOSE

32. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

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33. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

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34. SECURE STEERING WHEEL

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35. REMOVE COLUMN HOLE COVER SILENCER SHEET

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36. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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

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38. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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39. REMOVE DRIVE SHAFT ASSEMBLY

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40. REMOVE FRONT BUMPER LOWER ABSORBER

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41. REMOVE NO. 2 FRONT BUMPER REINFORCEMENT

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42. REMOVE FRONT BUMPER BAR REINFORCEMENT LH

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43. REMOVE FRONT BUMPER BAR REINFORCEMENT RH

(a) Use the same procedure as for the LH side.

44. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(1) 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.

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

(3) Remove the 3 bolts and nut and separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.

(4) Remove the bolt and No. 2 engine mounting stay LH.

(5) Remove the 12 bolts to separate the front suspension crossmember sub-assembly from the vehicle.

(6) 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.

45. REMOVE EMISSION CONTROL VALVE BRACKET

46. REMOVE WIRE HARNESS CLAMP BRACKET

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47. INSTALL ENGINE HANGERS

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

(1) Remove the engine mounting bracket cap.

(2) 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-W0313

(3) 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.

48. REMOVE ENGINE MOUNTING INSULATOR LH

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

49. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

50. REMOVE STARTER HOLE INSULATOR

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51. REMOVE FLYWHEEL HOUSING SIDE COVER

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

52. DISCONNECT HV AIR CONDITIONING WIRE

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Disengage the 2 clamps to disconnect the HV air conditioning wire from the hybrid vehicle transaxle assembly.

(2) Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the connector.

CAUTION:

Make sure to wear insulated gloves.

NOTICE:

Insulate the disconnected terminals and connector with insulating tape.

53. REMOVE ENGINE WIRE

HINT:

The illustrations are representative examples, and details may differ.

54. REMOVE MANIFOLD STAY

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55. REMOVE ENGINE ASSEMBLY

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56. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

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57. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

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58. REMOVE FLYWHEEL SUB-ASSEMBLY

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59. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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60. INSTALL ENGINE TO ENGINE STAND

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

61. REMOVE ENGINE HANGERS

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

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