Toyota Corolla Cross: Installation

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.

NOTICE:

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

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HINT:

Perform "Inspection After Repair" after replacing the engine assembly.

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CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	INSTALL ENGINE HANGERS	-		-	-
2	ENGINE FROM ENGINE STAND	-	-	-	-
3	NO. 1 CRANKSHAFT POSITION SENSOR PLATE	19315		-	-
4	FLYWHEEL SUB-ASSEMBLY	13405		-	-
5	TRANSMISSION INPUT DAMPER ASSEMBLY	31270		-	-
6	COMPRESSOR WITH MOTOR ASSEMBLY	88370		-	-
7	ENGINE ASSEMBLY	-		-	-
8	MANIFOLD STAY	17118	-	-	-
9	INSTALL ENGINE WIRE	82121	-	-	-

	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	★	Precoated part

Procedure		Part Name Code
10	HV AIR CONDITIONING WIRE	821H2		-	-
11	FLYWHEEL HOUSING SIDE COVER	11363A		-	-
12	STARTER HOLE INSULATOR	28193	-	-	-
13	ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH	12305		-	-
14	ENGINE MOUNTING INSULATOR LH	12372A		-	-
15	REMOVE ENGINE HANGERS	-	-	-	-
16	WIRE HARNESS CLAMP BRACKET	-	-	-	-
17	EMISSION CONTROL VALVE BRACKET	-	-	-	-
18	ENGINE ASSEMBLY WITH TRANSAXLE	-		-	-

*1	ENGINE MOUNTING BRACKET CAP	-	-
	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	-	-

FRONT BUMPER LOWER ABSORBER

Procedure		Part Name Code
19	FRONT BUMPER BAR REINFORCEMENT LH	52134C	-	-	-
20	FRONT BUMPER BAR REINFORCEMENT RH	52133C	-	-	-
21	NO. 2 FRONT BUMPER REINFORCEMENT	52132A	-	-	-
22	FRONT BUMPER LOWER ABSORBER	52618	-	-	-

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

-

-

Procedure		Part Name Code
23	DRIVE SHAFT ASSEMBLY	-	-	-	-
24	FRONT EXHAUST PIPE ASSEMBLY	17410		-	-
25	NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY	45025D		-	-
26	NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY	45260		-	-
27	COLUMN HOLE COVER SILENCER SHEET	45259A	-	-	-

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

-

-

Procedure		Part Name Code
28	SUCTION HOSE SUB-ASSEMBLY	88704		-	-
29	DISCHARGE HOSE SUB-ASSEMBLY	88703		-	-
30	FUEL TUBE SUB-ASSEMBLY	23901		-	-
31	WATER BY-PASS HOSE	16283B	-	-	-
32	OUTLET HEATER WATER HOSE	-		-	-
33	INLET HEATER WATER HOSE	-		-	-
34	PURGE VALVE (PURGE VSV)	25860	-	-	-
35	NO. 1 FUEL VAPOR FEED HOSE	23826	-	-	-
36	NO. 2 FUEL VAPOR FEED HOSE	23827A	-	-	-
37	NO. 3 FUEL VAPOR FEED HOSE	23827F	-	-	-
38	OUTLET NO. 1 HYBRID WATER PUMP HOSE	G922C	-	-	-
39	INLET HYBRID RADIATOR HOSE	G922H	-	-	-
40	NO. 2 RADIATOR HOSE	16572D	-	-	-
41	NO. 1 RADIATOR HOSE	16571C	-	-	-
42	TRANSMISSION CONTROL CABLE ASSEMBLY	33820B	-	-	-
43	INVERTER RESERVE TANK ASSEMBLY	G92A0A		-	-
44	CONNECT ENGINE WIRE	-	-	-	-
45	NO. 1 RELAY BLOCK COVER	82662A	-	-	-
46	INVERTER WITH CONVERTER ASSEMBLY	G92A0		-	-
47	NO. 1 AIR CLEANER INLET	17751	-	-	-

	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 11 or equivalent	-	-

Procedure		Part Name Code
48	ADD ENGINE OIL	-	-		-
49	ADD ENGINE COOLANT	-	-		-
50	ADD HYBRID TRANSAXLE FLUID	-	-		-
51	CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT	-	-		-
52	WARM UP COMPRESSOR	-		-	-
53	INSPECT HYBRID TRANSAXLE FLUID	-		-	-
54	INSPECT SHIFT LEVER POSITION	-		-	-
55	ADJUST SHIFT LEVER POSITION	-		-	-
56	INSPECT FOR ENGINE OIL LEAK	-		-	-
57	INSPECT FOR COOLANT LEAK	-		-	-
58	INSPECT FOR COOLANT LEAK	-		-	-
59	INSPECT FOR REFRIGERANT LEAK	-		-	-
60	INSPECT FOR FUEL LEAK	-		-	-
61	INSPECT FOR EXHAUST GAS LEAK	-		-	-
62	CHECK ENGINE OIL LEVEL	-		-	-
63	INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine)	-		-	-
64	FRONT BUMPER ASSEMBLY	-	-	-	-
65	REAR ENGINE UNDER COVER LH	51444A	-	-	-
66	REAR ENGINE UNDER COVER RH	51443C	-	-	-
67	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
68	FRONT WHEELS	-		-	-
69	ALIGN FRONT WHEELS FACING STRAIGHT AHEAD	-		-	-
70	INSPECT AND ADJUST FRONT WHEEL ALIGNMENT	-		-	-
71	PERFORM INITIALIZATION	-	-	-
72	INSPECT IGNITION TIMING	-		-	-
73	INSPECT ENGINE IDLE SPEED	-		-	-
74	INSPECT CO/HC	-		-	-
75	CHECK SPEED SENSOR SIGNAL	-		-	-

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

-

-

PROCEDURE

1. INSTALL ENGINE HANGERS

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2. REMOVE ENGINE FROM ENGINE STAND

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

3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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4. INSTALL FLYWHEEL SUB-ASSEMBLY

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5. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

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6. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

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7. INSTALL ENGINE ASSEMBLY

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8. INSTALL MANIFOLD STAY

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9. INSTALL ENGINE WIRE

Torque:

Bolt (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt (B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

HINT:

The illustrations are representative examples, and details may differ.

10. CONNECT HV AIR CONDITIONING WIRE

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.

CAUTION:

Make sure to wear insulated gloves.

NOTICE:

Make sure that the connector is connected securely.

(2) Engage the 2 clamps to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.

11. INSTALL FLYWHEEL HOUSING SIDE COVER

12. INSTALL STARTER HOLE INSULATOR

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13. 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) Engage the clamp.

(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}

14. 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).

(3) Engage the clamp.

15. REMOVE ENGINE HANGERS

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16. INSTALL WIRE HARNESS CLAMP BRACKET

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17. INSTALL EMISSION CONTROL VALVE BRACKET

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

18. 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 subassembly.

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 5 bolts and nut in the order shown in the illustration.

Torque:

Bolt (A), (B), (C) :

70 N·m {714 kgf·cm, 52 ft·lbf}

Bolt (D), (E) :

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 5 bolts and nut in the order of (D), (E), (A), (B) and (C).

(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}

19. INSTALL FRONT BUMPER BAR REINFORCEMENT LH

20. INSTALL FRONT BUMPER BAR REINFORCEMENT RH

21. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT

22. INSTALL FRONT BUMPER LOWER ABSORBER

23. INSTALL DRIVE SHAFT ASSEMBLY

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24. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

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26. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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27. INSTALL COLUMN HOLE COVER SILENCER SHEET

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28. CONNECT SUCTION HOSE SUB-ASSEMBLY

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29. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

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30. CONNECT FUEL TUBE SUB-ASSEMBLY

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

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(2) Engage the claw and install the No. 1 fuel pipe clamp as shown in the illustration.

31. CONNECT WATER BY-PASS HOSE

32. CONNECT OUTLET HEATER WATER HOSE

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

(1) Align the protrusions of the outlet heater water hose connector with the cutouts in the water hose sub-assembly and push them together until the outlet heater water hose connector makes a "click" sound.

(2) Push in the retainer.

(3) Check that the water hose sub-assembly and outlet heater water hose connector are securely connected by pulling on them.

33. CONNECT INLET HEATER WATER HOSE

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

(1) Align the protrusion of the water hose sub-assembly with the cutout in the inlet heater water hose connector and push them together until the inlet heater water hose makes a "click" sound.

(2) Push in the retainer.

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

34. INSTALL PURGE VALVE (PURGE VSV)

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35. INSTALL NO. 1 FUEL VAPOR FEED HOSE

36. INSTALL NO. 2 FUEL VAPOR FEED HOSE

37. INSTALL NO. 3 FUEL VAPOR FEED HOSE

38. CONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE

39. CONNECT INLET HYBRID RADIATOR HOSE

40. CONNECT NO. 2 RADIATOR HOSE

41. CONNECT NO. 1 RADIATOR HOSE

42. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

43. CONNECT INVERTER RESERVE TANK ASSEMBLY

(1) Connect the inverter reserve tank assembly with the 2 bolts.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

NOTICE:

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

44. CONNECT ENGINE WIRE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

45. INSTALL NO. 1 RELAY BLOCK COVER

46. INSTALL INVERTER WITH CONVERTER ASSEMBLY

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47. INSTALL INLET NO. 1 AIR CLEANER

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48. ADD ENGINE OIL

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49. ADD ENGINE COOLANT (for Engine)

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50. ADD HYBRID TRANSAXLE FLUID

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51. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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52. WARM UP COMPRESSOR

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53. INSPECT HYBRID TRANSAXLE FLUID

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54. INSPECT SHIFT LEVER POSITION

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55. ADJUST SHIFT LEVER POSITION

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56. INSPECT FOR ENGINE OIL LEAK

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57. INSPECT FOR COOLANT LEAK (for Inverter)

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58. INSPECT FOR COOLANT LEAK (for Engine)

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59. INSPECT FOR REFRIGERANT LEAK

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60. INSPECT FOR FUEL LEAK

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61. INSPECT FOR EXHAUST GAS LEAK

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62. CHECK ENGINE OIL LEVEL

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63. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine)

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64. INSTALL FRONT BUMPER ASSEMBLY

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65. INSTALL REAR ENGINE UNDER COVER LH

66. INSTALL REAR ENGINE UNDER COVER RH

67. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

68. INSTALL FRONT WHEELS

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69. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

70. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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71. PERFORM INITIALIZATION

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72. INSPECT IGNITION TIMING

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73. INSPECT ENGINE IDLE SPEED

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74. INSPECT CO/HC

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75. CHECK SPEED SENSOR SIGNAL

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