Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	LOOSEN NO. 1 EGR PIPE SUB-ASSEMBLY	25601		-	-
2	LOOSEN EGR VALVE ASSEMBLY	25620		-	-
3	NO. 1 EGR COOLER GASKET	25685		-	-
4	EGR VALVE GASKET	25627		-	-
5	EGR COOLER ASSEMBLY	25680		-	-
6	WIRE HARNESS CLAMP BRACKET	-	-	-	-
7	NO. 4 WATER BY-PASS HOSE	16281	-	-	-
8	NO. 3 WATER BY-PASS HOSE	16267	-	-	-
9	TIGHTEN EGR VALVE ASSEMBLY	25620		-	-
10	TIGHTEN NO. 1 EGR PIPE SUB-ASSEMBLY	25601		-	-
11	ENGINE WIRE	82121	-	-	-
12	AUXILIARY BATTERY	-	-	-	-
13	AIR CLEANER CAP WITH AIR CLEANER HOSE	-		-	-
14	ADD ENGINE COOLANT	-	-		-
15	INSPECT FOR COOLANT LEAK	-		-	-
16	INSPECT FOR EXHAUST GAS LEAK	-		-	-

*a	x2 or x3	*b	x3 or x2
	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	-	-

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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PROCEDURE

1. LOOSEN NO. 1 EGR PIPE SUB-ASSEMBLY

(1) Using an 8 mm socket wrench, loosen the 4 bolts of the No. 1 EGR pipe sub-assembly.

NOTICE:

• As the bolts of the No. 1 EGR pipe sub-assembly are only to be loosened, it is not necessary to replace the EGR inlet gasket and EGR valve adapter gasket.
• If the No. 1 EGR pipe sub-assembly is removed, it is necessary to replace the EGR inlet gasket and EGR valve adapter gasket with new ones.

2. LOOSEN EGR VALVE ASSEMBLY

(1) Using an 8 mm socket wrench, loosen the 2 bolts EGR valve assembly.

3. INSTALL NO. 1 EGR COOLER GASKET

(1) Install a new No. 1 EGR cooler gasket to the EGR cooler assembly.

NOTICE:

Make sure that the claws of the No. 1 EGR cooler gasket are toward the EGR cooler assembly side.

4. INSTALL EGR VALVE GASKET

(1) Install a new EGR valve gasket to the EGR cooler assembly.

NOTICE:

Make sure that the claws of the EGR valve gasket are toward the EGR cooler assembly side.

5. INSTALL EGR COOLER ASSEMBLY

[The illustrations are representative examples, and details may differ.]

(1) Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the bolts and nuts.

(2) Tighten the bolts and nuts in the order shown in the illustration.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

6. INSTALL WIRE HARNESS CLAMP BRACKET

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

7. CONNECT NO. 4 WATER BY-PASS HOSE

8. CONNECT NO. 3 WATER BY-PASS HOSE

9. TIGHTEN EGR VALVE ASSEMBLY

(1) Using an 8 mm socket wrench, tighten the 2 bolts of the EGR valve assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

10. TIGHTEN NO. 1 EGR PIPE SUB-ASSEMBLY

(1) Using an 8 mm socket wrench, tighten the 4 bolts of the No. 1 EGR pipe sub-assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

11. CONNECT ENGINE WIRE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

12. INSTALL AUXILIARY BATTERY

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13. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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14. ADD ENGINE COOLANT

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15. INSPECT FOR COOLANT LEAK

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16. INSPECT FOR EXHAUST GAS LEAK

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