Last Modified: 05-13-2024 |
6.11:8.1.0 |
Doc ID: RM1000000028TWL |
Model Year Start: 2023 |
Model: Corolla Hatchback |
Prod Date Range: [11/2022 -
] |
Title: M20A-FKS (INTAKE / EXHAUST): EXHAUST MANIFOLD (for Double Wishbone Type Suspension): INSTALLATION; 2023 - 2025 MY Corolla Corolla Hatchback [11/2022 - ] |
INSTALLATION
PROCEDURE
1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)
(a) Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.
(b) Using a 12 mm deep socket wrench, temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.
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(c) Using the 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.
Torque:
26 N·m {265 kgf·cm, 19 ft·lbf}
3. INSTALL MANIFOLD STAY
(a) Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.
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(b) Tighten the bolt and nut in the order shown in the illustration.
Torque:
43 N·m {438 kgf·cm, 32 ft·lbf}
4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
5. INSTALL AIR FUEL RATIO SENSOR
Click here
6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
for TMC Made: Click here
for TMMMS Made: Click here
7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)
(a) Using a vernier caliper, measure the free length of the compression springs.
Minimum Free Length (Front)
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41.5 mm (1.63 in.)
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Minimum Free Length (Rear)
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38.5 mm (1.52 in.)
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If the free length is less than the minimum, replace the compression spring.
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(b) Temporarily install 2 new gaskets to the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).
(c) Using a plastic hammer and wooden block, tap in each gasket until its surface is flush with the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).
NOTICE:
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Be sure to install the gasket in the correct direction.
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Do not reuse the gaskets.
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Do not damage the gaskets.
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Do not push in the gaskets by using the exhaust pipes when connecting them.
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*1
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Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
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*2
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Gasket
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*a
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Wooden Block
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(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
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Exhaust Manifold (TWC: Front Catalyst)
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*2
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Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
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*3
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Gasket
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*a
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Space between Flanges: 8.5 mm (0.335 in.)
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(f) Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the tail exhaust pipe assembly 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 front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.
*1
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Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
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*2
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Tail Exhaust Pipe Assembly
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*3
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Gasket
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*a
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Space between Flanges: 6.5 mm (0.256 in.)
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(g) Engage the wire harness clamp.
(h) Connect the air fuel ratio sensor connector.
8. INSTALL FRONT FLOOR CENTER BRACE
(a) for Hatchback:
(1) Install the 3 front floor center braces to the vehicle body with the 12 bolts.
Torque:
29 N·m {296 kgf·cm, 21 ft·lbf}
(b) except Hatchback:
(1) Install the 2 front floor center braces to the vehicle body with the 8 bolts.
Torque:
29 N·m {296 kgf·cm, 21 ft·lbf}
9. INSTALL FRONT FLOOR COVER LH
(a) for Hatchback:
(1) Engage the 6 clamps to install the front floor cover LH to the vehicle body with the 2 bolts and 3 clips.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
(b) except Hatchback:
(1) w/ Cover:
Engage the 6 clamps to install the front floor cover LH to the vehicle body with the 2 bolts and 3 clips.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
10. INSTALL FRONT FLOOR COVER RH
HINT:
Perform the same procedure as for the front floor cover LH.
11. INSPECT FOR EXHAUST GAS LEAK
Click here
12. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY
Click here
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