Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	STUD BOLT	-		-	-
2	WIRE HARNESS CLAMP BRACKET	-		-	-
3	NO. 2 VENTILATION HOSE	12262	-	-	-
4	VACUUM SURGE TANK BRACKET	25759A		-	-
5	VACUUM SURGE TANK	25719	-	-	-
6	PURGE VALVE (PURGE VSV)	25860	-	-	-
7	NO. 3 EXHAUST MANIFOLD HEAT INSULATOR	17169A	-	-	-
8	ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)	16032		-	-
9	WATER INLET WITH THERMOSTAT SUB-ASSEMBLY	16031	-	-	-
10	ENGINE OIL LEVEL DIPSTICK GUIDE	11452D	-	-	-
11	IGNITION COIL ASSEMBLY	19500		-	-

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

●

Non-reusable part

Procedure		Part Name Code
12	FUEL INJECTOR SEAL	23255A		-	-
13	INJECTOR VIBRATION INSULATOR	23291A		-	-
14	C-RING	-		-	-
15	NO. 1 FUEL INJECTOR BACK-UP RING	23256		-	-
16	NO. 3 FUEL INJECTOR BACK-UP RING	23258		-	-
17	NOZZLE HOLDER CLAMP	23695A		-	-
18	DIRECT FUEL INJECTOR ASSEMBLY	23250E		-	-
19	FUEL DELIVERY PIPE	23814B		-	-
20	PORT FUEL INJECTOR ASSEMBLY	23250F		-	-
21	NO. 5 ENGINE WIRE	82125N	-	-	-
22	INJECTOR VIBRATION INSULATOR	23291	-	-	-
23	FUEL DELIVERY SPACER	23891	-	-	-
24	FUEL DELIVERY PIPE SUB-ASSEMBLY	23807		-	-

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

●

Non-reusable part

Procedure		Part Name Code
25	NO. 6 ENGINE WIRE	82126A	-	-	-
26	SENSOR WIRE	82219C	-	-	-
27	NO. 1 WATER BY-PASS HOSE ASSEMBLY	-	-	-	-
28	FUEL PUMP LIFTER ASSY	23470		-	-
29	FUEL PUMP SPACER GASKET	23224D	-	-	-
30	FUEL PUMP FLANGE	23191	-	-	-
31	TEMPORARILY INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)	23100X		-	-
32	TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY	23801P		-	-
33	INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)	23100X		-	-
34	INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY	23801P		-	-
35	FUEL TUBE SUB-ASSEMBLY	23910A		-	-

	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	*	For use with a union nut wrench

Procedure		Part Name Code
36	INTAKE MANIFOLD	17111		-	-
37	NO. 1 FUEL VAPOR FEED HOSE	23826	-	-	-
38	INTAKE MANIFOLD STAY	17138B		-	-
39	INSTALL NO. 3 WATER BY-PASS PIPE	16279		-	-
40	EGR VALVE ASSEMBLY	25620		-	-
41	INSTALL NO. 4 WATER BY-PASS HOSE	16281	-	-	-
42	NO. 1 EGR COOLER GASKET	25685		-	-
43	EGR VALVE GASKET	25627		-	-
44	EGR COOLER ASSEMBLY	25680		-	-
45	WIRE HARNESS CLAMP BRACKET	-	-	-	-
46	CONNECT NO. 4 WATER BY-PASS HOSE	16281	-	-	-
47	CONNECT NO. 3 WATER BY-PASS HOSE	16267	-	-	-
48	EGR VALVE ASSEMBLY	25620		-	-
49	EGR INLET GASKET	25628	-	-	-
50	EGR VALVE ADAPTER GASKET	25629	-	-	-
51	NO. 1 EGR PIPE SUB-ASSEMBLY	25601		-	-
52	THROTTLE BODY GASKET	22271		-	-
53	CONNECT NO. 8 WATER BY-PASS HOSE	16296	-	-	-
54	CONNECT NO. 5 WATER BY-PASS HOSE	16282		-	-
55	THROTTLE BODY WITH MOTOR ASSEMBLY	22030	-	-	-
56	INSTALL NO. 8 WATER BY-PASS HOSE	16296		-	-

*A	Type A	*B	Type B
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part

Procedure		Part Name Code
57	EXHAUST MANIFOLD (TWC: Front Catalyst)	17141		-	-
58	NO. 1 EXHAUST MANIFOLD HEAT INSULATOR	17167		-	-
59	WATER HOSE CLAMP BRACKET	16575B	-	-	-
60	FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)	16260	-	-	-
61	NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY	16207		-	-
62	NO. 2 RADIATOR HOSE	16572D	-	-	-
63	V-RIBBED BELT TENSIONER ASSEMBLY	16620D	-	-	-
64	DRIVE SHAFT BEARING BRACKET	43457	-	-	-

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

●

Non-reusable part

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here

PROCEDURE

1. INSTALL STUD BOLT

*a	33.1 mm (1.30 in.)	*b	15 mm (0.591 in.)
*c	95 mm (3.74 in.)	-	-

(1) Using an E8 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

2. INSTALL WIRE HARNESS CLAMP BRACKET

(1) Install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(2) Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. INSTALL NO. 2 VENTILATION HOSE

4. INSTALL VACUUM SURGE TANK BRACKET

(1) Using an 8 mm socket wrench, install the vacuum surge tank bracket to the camshaft housing sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL VACUUM SURGE TANK

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

6. INSTALL PURGE VALVE (PURGE VSV)

Click here

7. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

8. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

Click here

9. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

Click here

10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

*1

OIL LEVEL GAGE SUB-ASSEMBLY

-

-

(1) Apply a light coat of engine oil to a new O-ring.

(2) Install the O-ring to the engine oil level dipstick guide.

(3) Using an 8 mm socket wrench, install the engine oil level dipstick guide to the cylinder head sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(4) Install the engine oil level dipstick.

11. INSTALL IGNITION COIL ASSEMBLY

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12. INSTALL FUEL INJECTOR SEAL

Click here

13. INSTALL INJECTOR VIBRATION INSULATOR

Click here

14. INSTALL C-RING

Click here

15. INSTALL NO. 1 FUEL INJECTOR BACK-UP RING

Click here

16. INSTALL NO. 3 FUEL INJECTOR BACK-UP RING

Click here

17. INSTALL NOZZLE HOLDER CLAMP

Click here

18. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

Click here

19. INSTALL FUEL DELIVERY PIPE

Click here

20. INSTALL PORT FUEL INJECTOR ASSEMBLY

Click here

21. INSTALL NO. 5 ENGINE WIRE

Click here

22. INSTALL INJECTOR VIBRATION INSULATOR

Click here

23. INSTALL FUEL DELIVERY SPACER

Click here

24. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here

25. INSTALL NO. 6 ENGINE WIRE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

26. INSTALL SENSOR WIRE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

27. INSTALL NO. 1 WATER BY-PASS HOSE ASSEMBLY

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

28. INSTALL FUEL PUMP LIFTER ASSY

29. INSTALL FUEL PUMP SPACER GASKET

30. INSTALL FUEL PUMP FLANGE

31. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

32. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here

33. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

34. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here

35. CONNECT FUEL TUBE SUB-ASSEMBLY

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

(2) Install the fuel pipe clamp to the fuel tube connector.

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

36. INSTALL INTAKE MANIFOLD

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37. CONNECT NO. 1 FUEL VAPOR FEED HOSE

Click here

38. INSTALL INTAKE MANIFOLD STAY

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39. INSTALL NO. 3 WATER BY-PASS PIPE

(1) Install the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.

(2) Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

40. SET EGR VALVE ASSEMBLY

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41. INSTALL NO. 4 WATER BY-PASS HOSE

42. INSTALL NO. 1 EGR COOLER GASKET

43. INSTALL EGR VALVE GASKET

Click here

44. INSTALL EGR COOLER ASSEMBLY

Click here

45. INSTALL WIRE HARNESS CLAMP BRACKET

Click here

46. CONNECT NO. 4 WATER BY-PASS HOSE

47. CONNECT NO. 3 WATER BY-PASS HOSE

48. INSTALL EGR VALVE ASSEMBLY

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49. INSTALL EGR INLET GASKET

Click here

50. INSTALL EGR VALVE ADAPTER GASKET

Click here

51. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

Click here

52. INSTALL THROTTLE BODY GASKET

53. CONNECT NO. 8 WATER BY-PASS HOSE

Click here

54. CONNECT NO. 5 WATER BY-PASS HOSE

Click here

55. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

56. INSTALL NO. 8 WATER BY-PASS HOSE

Click here

57. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

for 2WD: for AWD:

58. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

• for 2WD:

  Click here

• for AWD:

  Click here

59. INSTALL WATER HOSE CLAMP BRACKET

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

60. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

61. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

*a	2 to 13 mm (0.0787 to 0.5118 in.)	*b	60°
*c	Paint Mark	*d	Protrusion
*e	RH Side of Vehicle	-	-

(1) Install the No. 2 water by-pass pipe sub-assembly to the water hose clamp bracket with the bolt.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

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

NOTICE:

• Make sure to slide the No. 2 water by-pass pipe sub-assembly until it contacts the hose stopper of the water by-pass outlet sub-assembly.
• Make sure that the claws of the clip are within the location shown in the illustration.

62. INSTALL NO. 2 RADIATOR HOSE

63. INSTALL 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.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

64. INSTALL DRIVE SHAFT BEARING BRACKET (for AWD)

Torque:

63.7 N·m {650 kgf·cm, 47 ft·lbf}

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