2ZR-FXE (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL; 2023 - 2025 MY Corolla Corolla HV [09/2022

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM10000000261GM
Model Year Start: 2023	Model: Corolla	Prod Date Range: [09/2022 - ]
Title: 2ZR-FXE (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL; 2023 - 2025 MY Corolla Corolla HV [09/2022 - ]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during exhaust manifold (TWC: Front Catalyst) removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of air fuel ratio sensor Gas leaks from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

PROCEDURE

1. REMOVE HEATED OXYGEN SENSOR

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2. REMOVE FRONT FLOOR COVER LH

(a) Remove the 2 bolts and 3 clips and disengage the 6 clamps to remove the front floor cover LH from the vehicle body.

	Bolt
	Clip

3. REMOVE FRONT FLOOR COVER RH

HINT:

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

4. REMOVE FRONT FLOOR CENTER BRACE

(a) Remove the 12 bolts and 3 front floor center braces from the vehicle body.

5. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

CAUTION:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

(a) Disconnect the heated oxygen sensor connector.

(b) Disengage the wire harness clamp.

(c) Remove the 4 bolts and 4 compression springs and disconnect the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust manifold (TWC: Front Catalyst) and tail exhaust pipe assembly.

(d) Remove the front exhaust pipe assembly (TWC: Rear Catalyst) from the 2 exhaust pipe supports.

(e) Remove the 2 gaskets from the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

6. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

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7. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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8. DISCONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

(a) Remove the bolt and disconnect the floor shift transmission control select cable from the engine assembly.

9. REMOVE WIRING HARNESS CLAMP BRACKET

CAUTION:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

(a) Disengage the clamp and remove the bolt and wiring harness clamp bracket from the engine assembly.

10. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

CAUTION:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

(a) Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).

11. REMOVE MANIFOLD STAY

CAUTION:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

(a) Remove the 3 bolts and manifold stay from the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly.

12. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

CAUTION:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

(a) Remove the 7 nuts and exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly.

(b) Remove the exhaust manifold to head gasket and EGR cooler gasket from the cylinder head sub-assembly.

*1	Exhaust Manifold To Head Gasket
*2	EGR Cooler Gasket

13. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 3 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).