M20A-FKS (INTAKE / EXHAUST): EXHAUST PIPE (for Torsion Beam Type Suspension): INSTALLATION; 2023 - 2025 MY Corolla Corolla Hatchback [09/2022

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM1000000025JJ2
Model Year Start: 2023	Model: Corolla Hatchback	Prod Date Range: [09/2022 - ]
Title: M20A-FKS (INTAKE / EXHAUST): EXHAUST PIPE (for Torsion Beam Type Suspension): INSTALLATION; 2023 - 2025 MY Corolla Corolla Hatchback [09/2022 - ]

INSTALLATION

PROCEDURE

1. INSTALL AIR FUEL RATIO SENSOR

Click here

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 3 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 air fuel ratio 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 3 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

Click here

5. INSPECT FOR EXHAUST GAS LEAK

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

HINT:

Perform "Inspection After Repairs" after repairing or replacing the exhaust system.

Click here