2ZR-FXE (INTAKE / EXHAUST): EXHAUST PIPE: INSTALLATION; 2020 - 2025 MY Corolla Corolla HV [01/2019

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM100000001GFQM
Model Year Start: 2020	Model: Corolla	Prod Date Range: [01/2019 - ]
Title: 2ZR-FXE (INTAKE / EXHAUST): EXHAUST PIPE: INSTALLATION; 2020 - 2025 MY Corolla Corolla HV [01/2019 - ]

INSTALLATION

PROCEDURE

1. INSTALL HEATED OXYGEN SENSOR

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

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

Minimum Free Length

41.5 mm (1.63 in.)

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

(b) Temporarily install a new gasket to the exhaust manifold (TWC: Front Catalyst).

(c) Using a plastic hammer and wooden block, tap in the gasket until its surface is flush with the exhaust manifold (TWC: Front Catalyst).

NOTICE:

Be careful with the installation direction of the gasket.
Do not reuse the gasket.
Do not damage the gasket.
Do not push in the gasket by using the exhaust pipes when connecting them.

*1	Exhaust Manifold (TWC: Front Catalyst)
*2	Gasket
*a	Wooden Block

(d) Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.

(e) 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}

HINT:

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.

*1	Exhaust Manifold (TWC: Front Catalyst)
*2	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*3	Gasket
*a	Space between Flanges: 8.5 mm (0.335 in.)

(f) Engage the wire harness clamp.

(g) Connect the heated oxygen sensor connector.

3. INSTALL TAIL EXHAUST PIPE ASSEMBLY

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

Minimum Free Length

38.5 mm (1.52 in.)

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

(b) Temporarily install a new gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).

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

NOTICE:

Be careful with the installation direction of the gasket.
Do not reuse the gasket.
Do not damage the gasket.
Do not push in the gasket by using the exhaust pipes when connecting them.

*1	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*2	Gasket
*a	Wooden Block

(d) Connect the tail exhaust pipe assembly to the 4 exhaust pipe supports.

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

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

HINT:

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

*1	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*2	Tail Exhaust Pipe Assembly
*3	Gasket
*a	Space between Flanges: 6.5 mm (0.256 in.)

4. INSTALL FRONT FLOOR CENTER BRACE

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5. INSTALL FRONT FLOOR COVER LH

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6. INSTALL FRONT FLOOR COVER RH

HINT:

Perform the same procedure as for the front floor cover LH.

7. INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

(a) Perform "Inspection After Repair" after repairing an exhaust gas leak.

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