Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	NO. 2 EXHAUST MANIFOLD HEAT INSULATOR	17168	-	-	-
2	EXHAUST MANIFOLD (TWC: Front Catalyst)	17141		-	-
3	MANIFOLD STAY	17118		-	-
4	NO. 1 EXHAUST MANIFOLD HEAT INSULATOR	17167		-	-
5	DASH PANEL HEAT INSULATOR	55225C	-	-	-
6	WIRE HARNESS CLAMP BRACKET	-	-	-	-
7	AIR FUEL RATIO SENSOR	89467B	-	-	-
8	FRONT NO. 1 FLOOR HEAT INSULATOR	58151	-	-	-
9	PROPELLER SHAFT HEAT INSULATOR	37117B	-	-	-
10	PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY	37100	-	-	-
11	FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)	17410		-	-
12	FRONT FLOOR CENTER BRACE	57533B	-	-	-
13	INSPECT FOR EXHAUST GAS LEAK	-		-	-
14	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-

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

●

Non-reusable part

PROCEDURE

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

(1) Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

(2) Using a 12 mm deep socket wrench, temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.

(3) Using the 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

3. INSTALL MANIFOLD STAY

(1) Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.

(2) Tighten the bolt and nut in the order shown in the illustration.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL DASH PANEL HEAT INSULATOR

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

6. INSTALL WIRE HARNESS CLAMP BRACKET

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

7. INSTALL AIR FUEL RATIO SENSOR

Click here

8. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

(1) Install the clip.

(2) Install the nut.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(3) Using a 10 mm union nut wrench, Install the No. 1 exhaust manifold heat insulator with the nut.

Torque:

Specified tightening torque :

5.0 N·m {51 kgf·cm, 44 in·lbf}

HINT:

• Calculate the torque wrench reading when changing the fulcrum length of the torque wrench

  Click here

• When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 4.4 N*m (44 kgf*cm, 38 in.*lbf)

9. INSTALL PROPELLER SHAFT HEAT INSULATOR

(1) Install the propeller shaft heat insulator with the 4 bolts.

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

NOTICE:

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

10. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

Click here

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

(1) Using a vernier caliper, measure the free length of the compression springs.

If the free length is less than the minimum, replace the compression spring.

(2) temporarily install 2 new gaskets to the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

(3) Using a plastic hammer and wooden block, tap in each gasket until its surface is flush with the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

NOTICE:

• Be sure to install the gasket in the correct direction.
• Do not reuse the gaskets.
• Do not damage the gaskets.
• Do not push in the gaskets by using the exhaust pipes when connecting them.

(1) Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.

(2) Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) with the 2 compression springs and 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(3) After installation, check that the space between the flanges of the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

(4) Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(5) After installation, check that the space between the flanges of the front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

(6) Engage the wire harness clamp.

(7) Connect the heated oxygen sensor connector.

12. INSTALL FRONT FLOOR CENTER BRACE

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

13. INSPECT FOR EXHAUST GAS LEAK

Click here

14. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

Click here

READ NEXT: