Toyota Corolla Cross: Installation

INSTALLATION

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.

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CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	WIRE HARNESS CLAMP BRACKET	-		-	-
2	NO. 3 EXHAUST MANIFOLD HEAT INSULATOR	17169A	-	-	-
3	ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)	16032	-	-	-
4	WATER INLET WITH THERMOSTAT SUB-ASSEMBLY	16031		-	-
5	ENGINE OIL LEVEL DIPSTICK GUIDE	11452D	-	-	-
6	IGNITION COIL ASSEMBLY	19500		-	-

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

●

Non-reusable part

Procedure		Part Name Code
7	INJECTOR SEAL	23255A		-	-
8	INJECTOR VIBRATION INSULATOR	23291A		-	-
9	C-RING	-		-	-
10	NO. 1 FUEL INJECTOR BACK-UP RING	23256		-	-
11	NO. 3 FUEL INJECTOR BACK-UP RING	23258		-	-
12	NOZZLE HOLDER CLAMP	23695A	-	-	-
13	DIRECT FUEL INJECTOR ASSEMBLY	23250E		-	-
14	FUEL DELIVERY PIPE	23814B		-	-
15	PORT FUEL INJECTOR ASSEMBLY	23250F		-	-
16	NO. 5 ENGINE WIRE	82125N	-	-	-
17	INJECTOR VIBRATION INSULATOR	23291	-	-	-
18	FUEL DELIVERY SPACER	23891	-	-	-
19	FUEL DELIVERY PIPE SUB-ASSEMBLY	23807		-	-
20	NO. 6 ENGINE WIRE	82126A	-	-	-
21	SENSOR WIRE	82219C	-	-	-
22	WATER BY-PASS HOSE ASSEMBLY	-	-	-	-
23	FUEL PUMP LIFTER ASSEMBLY	23470		-	-
24	FUEL PUMP SPACER GASKET	23224D	-	-	-
25	FUEL PUMP FLANGE	23191	-	-	-
26	TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)	23100X		-	-
27	TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY	23801P		-	-
28	INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)	23100X		-	-
29	INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY	23801P		-	-
30	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 SST

Procedure		Part Name Code
31	NO. 1 INTAKE MANIFOLD TO HEAD GASKET	17177	-	-	-
32	INTAKE MANIFOLD	17111		-	-
33	INTAKE MANIFOLD STAY	17138B		-	-
34	NO. 3 WATER BY-PASS PIPE	16279		-	-
35	EGR VALVE ASSEMBLY	25620		-	-
36	NO. 8 WATER BY-PASS HOSE	16296	-	-	-
37	NO. 4 WATER BY-PASS HOSE	16281	-	-	-
38	EGR INLET GASKET	25628	-	-	-
39	EGR VALVE ADAPTER GASKET	25629	-	-	-
40	NO. 1 EGR PIPE SUB-ASSEMBLY	25601		-	-
41	NO. 1 EGR COOLER GASKET	25685		-	-
42	EGR VALVE GASKET	25627		-	-
43	EGR COOLER ASSEMBLY	25680		-	-
44	NO. 4 WATER BY-PASS HOSE	16281	-	-	-
45	NO. 3 WATER BY-PASS HOSE	16267	-	-	-
46	THROTTLE BODY GASKET	22271		-	-
47	THROTTLE BODY WITH MOTOR ASSEMBLY	22030		-	-

*a	x2 or x3	*b	x3 or x2
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part

Procedure		Part Name Code
48	MANIFOLD STAY	17118	-	-	-
49	EXHAUST MANIFOLD	17141		-	-
50	NO. 1 EXHAUST MANIFOLD HEAT INSULATOR	17167	-	-	-
51	FUEL HOSE BRACKET	23881B	-	-	-
52	NO. 2 RADIATOR HOSE	16572D	-	-	-

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

●

Non-reusable part

PROCEDURE

1. INSTALL WIRE HARNESS CLAMP BRACKET

(1) Install the wire harness clamp bracket to the stiffening crankcase 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}

2. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

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

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

4. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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5. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

6. INSTALL IGNITION COIL ASSEMBLY

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7. INSTALL FUEL INJECTOR SEAL

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8. INSTALL INJECTOR VIBRATION INSULATOR

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9. INSTALL C-RING

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

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

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12. INSTALL NOZZLE HOLDER CLAMP

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13. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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14. INSTALL FUEL DELIVERY PIPE

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15. INSTALL PORT FUEL INJECTOR ASSEMBLY

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16. INSTALL NO. 5 ENGINE WIRE

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17. INSTALL INJECTOR VIBRATION INSULATOR

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18. INSTALL FUEL DELIVERY SPACER

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19. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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20. INSTALL NO. 6 ENGINE WIRE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

21. INSTALL SENSOR WIRE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

22. INSTALL WATER BY-PASS HOSE ASSEMBLY

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

23. INSTALL FUEL PUMP LIFTER ASSEMBLY

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24. INSTALL FUEL PUMP SPACER GASKET

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25. SET FUEL PUMP FLANGE

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

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

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

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29. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(1) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

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

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• When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

(2) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

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

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• When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

(3) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

30. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel delivery pipe with sensor assembly.

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

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

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31. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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32. INSTALL INTAKE MANIFOLD

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33. INSTALL INTAKE MANIFOLD STAY

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34. 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}

35. INSTALL EGR VALVE ASSEMBLY

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36. CONNECT NO. 8 WATER BY-PASS HOSE

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37. CONNECT NO. 4 WATER BY-PASS HOSE

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38. INSTALL EGR INLET GASKET

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39. INSTALL EGR VALVE ADAPTER GASKET

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40. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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41. INSTALL NO. 1 EGR COOLER GASKET

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42. INSTALL EGR VALVE GASKET

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43. INSTALL EGR COOLER ASSEMBLY

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44. CONNECT NO. 4 WATER BY-PASS HOSE

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45. CONNECT NO. 3 WATER BY-PASS HOSE

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46. INSTALL THROTTLE BODY GASKET

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47. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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48. INSTALL MANIFOLD STAY

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49. INSTALL EXHAUST MANIFOLD

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50. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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51. INSTALL FUEL HOSE BRACKET

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

52. CONNECT NO. 2 RADIATOR HOSE

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