Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	INSTALL ENGINE HANGER	-		-	-
2	ENGINE ASSEMBLY FROM ENGINE STAND	-		-	-
3	COMPRESSOR ASSEMBLY WITH PULLEY	88310		-	-
4	GENERATOR ASSEMBLY	27020	-	-	-
5	V-RIBBED BELT	16361A		-	-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
6	NO. 1 CRANKSHAFT POSITION SENSOR PLATE	19315		-	-
7	DRIVE PLATE AND RING GEAR SUB-ASSEMBLY	32101B		-	-
8	ENGINE ASSEMBLY	-		-	-
9	WATER BY-PASS HOSE ASSEMBLY	16260	-	-	-
10	WATER INLET HOSE	16262	-	-	-
11	ENGINE WIRE	82121		-	-
12	FLYWHEEL HOUSING SIDE COVER	11363A	-	-	-
13	STARTER ASSEMBLY	28100	-	-	-
14	ENGINE ROOM MAIN WIRE	82111	-	-	-

	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
★	Precoated part	-	-
	Adhesive 1324	-	-

Procedure		Part Name Code
15	ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH	12305		-	-
16	ENGINE MOUNTING INSULATOR LH	12372A		-	-
17	REMOVE ENGINE HANGER	-	-	-	-
18	FUEL DELIVERY GUARD	23825	-	-	-
19	ENGINE ASSEMBLY WITH TRANSAXLE	-		-	-
20	DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT	32101G		-	-
21	FLYWHEEL HOUSING UNDER COVER	12321B	-	-	-
22	DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY	43409E	-	-	-
23	MANIFOLD STAY	11361J	-	-	-

*A	for 2WD	-	-
*a	BLACK COLOR: x 1 SILVER COLOR: x 5	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
	Adhesive 1324	-	-

FRONT BUMPER LOWER ABSORBER

Procedure		Part Name Code
24	FRONT BUMPER BAR REINFORCEMENT LH	52618	-	-	-
25	FRONT BUMPER BAR REINFORCEMENT RH	52132A	-	-	-
26	NO. 2 FRONT BUMPER REINFORCEMENT	52134C	-	-	-
27	FRONT BUMPER LOWER ABSORBER	52133C	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

Procedure		Part Name Code
28	DRIVE SHAFT ASSEMBLY	-	-	-	-
29	PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY	37100	-	-	-
30	FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)	17410	-	-	-
31	NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY	45025D		-	-
32	NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY	45260		-	-
33	COLUMN HOLE COVER SILENCER SHEET	45259A	-	-	-

*A	for 2WD	*B	for AWD
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)	-	-

Procedure		Part Name Code
34	SUCTION HOSE SUB-ASSEMBLY	88704		-	-
35	DISCHARGE HOSE SUB-ASSEMBLY	88703		-	-
36	NO. 2 WATER BY-PASS HOSE	16264D	-	-	-
37	FUEL TUBE SUB-ASSEMBLY	23901		-	-
38	INLET HEATER WATER HOSE	87245		-	-
39	OUTLET HEATER WATER HOSE	87246		-	-
40	NO. 1 FUEL VAPOR FEED HOSE	23829A	-	-	-
41	NO. 1 VACUUM HOSE CONNECTOR	44777	-	-	-
42	NO. 2 RADIATOR HOSE	16572D	-	-	-
43	NO. 1 RADIATOR HOSE	16571C	-	-	-
44	TRANSMISSION CONTROL CABLE ASSEMBLY	33820B		-	-
45	BATTERY CLAMP SUB-ASSEMBLY	74404A	-	-	-
46	ENGINE WIRE	-	-	-	-
47	ECM	89661	-	-	-

	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque
●	Non-reusable part	-	-
	Compressor oil ND-OIL 8 or equivalent	-	-

Procedure		Part Name Code
48	BATTERY	-	-	-	-
49	ADD TRANSFER OIL
50	ADD ENGINE OIL	-	-		-
51	ADD ENGINE COOLANT	-	-		-
52	ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID	-	-		-
53	CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT	-	-		-
54	WARM UP ENGINE	-		-	-
55	INSPECT SHIFT LEVER POSITION	-		-	-
56	ADJUST SHIFT LEVER POSITION	-		-	-
57	INSPECT FOR ENGINE OIL LEAK	-		-	-
58	INSPECT FOR COOLANT LEAK	-		-	-
59	INSPECT FOR TRANSFER OIL LEAK
60	INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK	-		-	-
61	INSPECT FOR REFRIGERANT LEAK	-		-	-
62	INSPECT FOR FUEL LEAK	-		-	-
63	INSPECT FOR EXHAUST GAS LEAK	-		-	-
64	CHECK ENGINE OIL LEVEL	-		-	-
65	INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL	-		-	-
66	FRONT BUMPER ASSEMBLY
67	REAR ENGINE UNDER COVER LH	51444A	-	-	-
68	REAR ENGINE UNDER COVER RH	51443C	-	-	-
69	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
70	FRONT WHEELS	-	-	-	-
71	INSPECT AND ADJUST FRONT WHEEL ALIGNMENT	-		-	-
72	END POSITION INITIAL SETTING	-	-	-
73	PERFORM INITIALIZATION	-	-	-
74	INSPECT IGNITION TIMING	-		-	-
75	INSPECT ENGINE IDLE SPEED	-		-	-
76	INSPECT CO/HC	-		-	-
77	CHECK SPEED SENSOR SIGNAL	-		-	-

*A	for AWD	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

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 ASSEMBLY FROM ENGINE STAND

3. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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4. INSTALL GENERATOR ASSEMBLY

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5. INSTALL V-RIBBED BELT

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6. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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8. INSTALL ENGINE ASSEMBLY

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9. CONNECT WATER BY-PASS HOSE ASSEMBLY

10. CONNECT WATER INLET HOSE

11. INSTALL ENGINE WIRE

HINT:

The illustrations are representative examples, and details may differ.

Torque:

Bolt (A), Nut (C) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt (B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

12. INSTALL FLYWHEEL HOUSING SIDE COVER

13. INSTALL STARTER ASSEMBLY

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14. INSTALL ENGINE ROOM MAIN WIRE

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15. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

(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:

Bolt (D), Nut (E) :

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}

16. INSTALL ENGINE MOUNTING INSULATOR LH

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

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

(2) 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).

17. REMOVE ENGINE HANGER

18. INSTALL FUEL DELIVERY GUARD

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(1) 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.

(2) 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 assembly with transaxle 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.

(3) Connect the front suspension crossmember sub-assembly to the vehicle with the 12 bolts.

Torque:

Bolt (A) :

32 N·m {326 kgf·cm, 24 ft·lbf}

Bolt (B) :

70 N·m {714 kgf·cm, 52 ft·lbf}

Bolt (C) :

141 N·m {1438 kgf·cm, 104 ft·lbf}

(4) Install the engine mounting insulator LH to the engine mounting bracket LH with the through bolt and nut in the order shown in the illustration.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

NOTICE:

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

(5) 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}

20. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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21. INSTALL FLYWHEEL HOUSING UNDER COVER

22. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY (for 2WD)

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23. INSTALL MANIFOLD STAY

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24. INSTALL FRONT BUMPER BAR REINFORCEMENT LH

25. INSTALL FRONT BUMPER BAR REINFORCEMENT RH

26. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT

27. INSTALL FRONT BUMPER LOWER ABSORBER

28. INSTALL DRIVE SHAFT ASSEMBLY

• for 2WD

  Click here

• for AWD

  Click here

29. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

30. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (for 2WD)

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

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32. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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33. INSTALL COLUMN HOLE COVER SILENCER SHEET

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34. CONNECT SUCTION HOSE SUB-ASSEMBLY

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35. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

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36. CONNECT NO. 2 WATER BY-PASS HOSE

37. CONNECT FUEL TUBE SUB-ASSEMBLY

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

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

38. CONNECT INLET HEATER WATER HOSE

*a	Protrusion	*b	Cutout
*c	Retainer	-	-
	Push		Push in

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

(2) Push in the retainer.

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

39. CONNECT OUTLET HEATER WATER HOSE

*a	Protrusion	*b	Cutout
*c	Retainer	-	-
	Push		Push in

(1) 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.

(2) Push in the retainer.

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

40. CONNECT NO. 1 FUEL VAPOR FEED HOSE

41. CONNECT NO. 1 VACUUM HOSE CONNECTOR

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42. CONNECT NO. 2 RADIATOR HOSE

43. CONNECT NO. 1 RADIATOR HOSE

44. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

*a

N

-

-

(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

*a

Correct

*b

Incorrect

(1) Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(2) Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

45. INSTALL BATTERY CLAMP SUB-ASSEMBLY

Torque:

15.4 N·m {157 kgf·cm, 11 ft·lbf}

46. CONNECT ENGINE WIRE

Torque:

Bolt (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut (B) :

7.6 N·m {77 kgf·cm, 67 in·lbf}

47. INSTALL ECM

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48. INSTALL BATTERY

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49. ADD TRANSFER OIL (for AWD)

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50. ADD ENGINE OIL

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51. ADD ENGINE COOLANT

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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

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57. INSPECT FOR ENGINE OIL LEAK

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58. INSPECT FOR COOLANT LEAK

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59. INSPECT FOR TRANSFER OIL LEAK (for AWD)

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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

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64. CHECK ENGINE OIL LEVEL

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65. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL

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66. INSTALL FRONT BUMPER ASSEMBLY

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67. INSTALL REAR ENGINE UNDER COVER LH

68. INSTALL REAR ENGINE UNDER COVER RH

69. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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 END POSITION INITIAL SETTING

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73. PERFORM INITIALIZATION

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74. INSPECT IGNITION TIMING

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75. INSPECT ENGINE IDLE SPEED

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76. INSPECT CO/HC

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77. CHECK SPEED SENSOR SIGNAL

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