Toyota Corolla Cross Owners & Service Manuals

Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure

Part Name Code

1

INSTALL ENGINE HANGER

-

-

-

2

ENGINE ASSEMBLY FROM ENGINE STAND

-

-

-

3

COMPRESSOR ASSEMBLY WITH PULLEY

88310

-

-

4

GENERATOR ASSEMBLY

27020

-

-

-

5

V-RIBBED BELT

16361A

-

-

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

Procedure

Part Name Code

6

NO. 1 CRANKSHAFT POSITION SENSOR PLATE

19315

-

-

7

DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

32101B

-

-

8

ENGINE ASSEMBLY

-

-

-

9

WATER BY-PASS HOSE ASSEMBLY

16260

-

-

-

10

WATER INLET HOSE

16262

-

-

-

11

ENGINE WIRE

82121

-

-

12

FLYWHEEL HOUSING SIDE COVER

11363A

-

-

-

13

STARTER ASSEMBLY

28100

-

-

-

14

ENGINE ROOM MAIN WIRE

82111

-

-

-

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

Precoated part

-

-

Adhesive 1324

-

-

Procedure

Part Name Code

15

ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

12305

-

-

16

ENGINE MOUNTING INSULATOR LH

12372A

-

-

17

REMOVE ENGINE HANGER

-

-

-

-

18

FUEL DELIVERY GUARD

23825

-

-

-

19

ENGINE ASSEMBLY WITH TRANSAXLE

-

-

-

20

DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

32101G

-

-

21

FLYWHEEL HOUSING UNDER COVER

12321B

-

-

-

22

DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

43409E

-

-

-

23

MANIFOLD STAY

11361J

-

-

-

*A

for 2WD

-

-

*a

BLACK COLOR: x 1

SILVER COLOR: x 5

-

-

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

Adhesive 1324

-

-

FRONT BUMPER LOWER ABSORBER

Procedure

Part Name Code

24

FRONT BUMPER BAR REINFORCEMENT LH

52618

-

-

-

25

FRONT BUMPER BAR REINFORCEMENT RH

52132A

-

-

-

26

NO. 2 FRONT BUMPER REINFORCEMENT

52134C

-

-

-

27

FRONT BUMPER LOWER ABSORBER

52133C

-

-

-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

Procedure

Part Name Code

28

DRIVE SHAFT ASSEMBLY

-

-

-

-

29

PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

37100

-

-

-

30

FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

17410

-

-

-

31

NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

45025D

-

-

32

NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

45260

-

-

33

COLUMN HOLE COVER SILENCER SHEET

45259A

-

-

-

*A

for 2WD

*B

for AWD

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

-

-

Procedure

Part Name Code

34

SUCTION HOSE SUB-ASSEMBLY

88704

-

-

35

DISCHARGE HOSE SUB-ASSEMBLY

88703

-

-

36

NO. 2 WATER BY-PASS HOSE

16264D

-

-

-

37

FUEL TUBE SUB-ASSEMBLY

23901

-

-

38

INLET HEATER WATER HOSE

87245

-

-

39

OUTLET HEATER WATER HOSE

87246

-

-

40

NO. 1 FUEL VAPOR FEED HOSE

23829A

-

-

-

41

NO. 1 VACUUM HOSE CONNECTOR

44777

-

-

-

42

NO. 2 RADIATOR HOSE

16572D

-

-

-

43

NO. 1 RADIATOR HOSE

16571C

-

-

-

44

TRANSMISSION CONTROL CABLE ASSEMBLY

33820B

-

-

45

BATTERY CLAMP SUB-ASSEMBLY

74404A

-

-

-

46

ENGINE WIRE

-

-

-

-

47

ECM

89661

-

-

-

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

-

-

Compressor oil ND-OIL 8 or equivalent

-

-

Procedure

Part Name Code

48

BATTERY

-

-

-

-

49

ADD TRANSFER OIL

       

50

ADD ENGINE OIL

-

-

-

51

ADD ENGINE COOLANT

-

-

-

52

ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

-

-

-

53

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

-

-

-

54

WARM UP ENGINE

-

-

-

55

INSPECT SHIFT LEVER POSITION

-

-

-

56

ADJUST SHIFT LEVER POSITION

-

-

-

57

INSPECT FOR ENGINE OIL LEAK

-

-

-

58

INSPECT FOR COOLANT LEAK

-

-

-

59

INSPECT FOR TRANSFER OIL LEAK

       

60

INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK

-

-

-

61

INSPECT FOR REFRIGERANT LEAK

-

-

-

62

INSPECT FOR FUEL LEAK

-

-

-

63

INSPECT FOR EXHAUST GAS LEAK

-

-

-

64

CHECK ENGINE OIL LEVEL

-

-

-

65

INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL

-

-

-

66

FRONT BUMPER ASSEMBLY

       

67

REAR ENGINE UNDER COVER LH

51444A

-

-

-

68

REAR ENGINE UNDER COVER RH

51443C

-

-

-

69

NO. 1 ENGINE UNDER COVER ASSEMBLY

51410

-

-

-

70

FRONT WHEELS

-

-

-

-

71

INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

-

-

-

72

END POSITION INITIAL SETTING

-

-

-

73

PERFORM INITIALIZATION

-

-

-

74

INSPECT IGNITION TIMING

-

-

-

75

INSPECT ENGINE IDLE SPEED

-

-

-

76

INSPECT CO/HC

-

-

-

77

CHECK SPEED SENSOR SIGNAL

-

-

-

*A

for AWD

-

-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

HINT:

Perform "Inspection After Repair" after replacing the engine assembly.

Click here

PROCEDURE

1. INSTALL ENGINE HANGER

Click here

2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

3. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

Click here

4. INSTALL GENERATOR ASSEMBLY

Click here

5. INSTALL V-RIBBED BELT

Click here

6. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Click here

7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

8. INSTALL ENGINE ASSEMBLY

Click here

9. CONNECT WATER BY-PASS HOSE ASSEMBLY

10. CONNECT WATER INLET HOSE

11. INSTALL ENGINE WIRE

HINT:

The illustrations are representative examples, and details may differ.

Torque:

Bolt (A), Nut (C) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt (B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

12. INSTALL FLYWHEEL HOUSING SIDE COVER

13. INSTALL STARTER ASSEMBLY

Click here

14. INSTALL ENGINE ROOM MAIN WIRE

Click here

15. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(1) Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

(2) Install the 2 bolts and nut in the order shown in the illustration.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

(3) Connect the air conditioner tube and accessory assembly with the bolt and nut.

Torque:

Bolt (D), Nut (E) :

9.8 N·m {100 kgf·cm, 87 in·lbf}

(4) Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

Torque:

10.5 N·m {107 kgf·cm, 8 ft·lbf}

16. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

(1) Temporarily install the engine mounting insulator LH to the vehicle.

(2) Install the 4 bolts and nut in the order shown in the illustration.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 4 bolts and nut in the order of (B), (C), (D), (A) and (E).

17. REMOVE ENGINE HANGER

18. INSTALL FUEL DELIVERY GUARD

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(1) Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.

NOTICE:

  • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.
  • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

(2) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.

NOTICE:

  • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
  • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

(3) Connect the front suspension crossmember sub-assembly to the vehicle with the 12 bolts.

Torque:

Bolt (A) :

32 N·m {326 kgf·cm, 24 ft·lbf}

Bolt (B) :

70 N·m {714 kgf·cm, 52 ft·lbf}

Bolt (C) :

141 N·m {1438 kgf·cm, 104 ft·lbf}

(4) Install the engine mounting insulator LH to the engine mounting bracket LH with the through bolt and nut in the order shown in the illustration.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

NOTICE:

While holding the nut in place, tighten the through bolt.

(5) Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

41 N·m {418 kgf·cm, 30 ft·lbf}

20. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click here

21. INSTALL FLYWHEEL HOUSING UNDER COVER

22. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY (for 2WD)

Click here

23. INSTALL MANIFOLD STAY

Click here

24. INSTALL FRONT BUMPER BAR REINFORCEMENT LH

25. INSTALL FRONT BUMPER BAR REINFORCEMENT RH

26. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT

27. INSTALL FRONT BUMPER LOWER ABSORBER

28. INSTALL DRIVE SHAFT ASSEMBLY

  • for 2WD

    Click here

  • for AWD

    Click here

29. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

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

Click here

31. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click here

32. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

33. INSTALL COLUMN HOLE COVER SILENCER SHEET

Click here

34. CONNECT SUCTION HOSE SUB-ASSEMBLY

Click here

35. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

Click here

36. CONNECT NO. 2 WATER BY-PASS HOSE

37. CONNECT FUEL TUBE SUB-ASSEMBLY

(1) Connect the fuel tube sub-assembly to the fuel pump assembly.

Click here

(2) Engage the clamp to connect the fuel tube sub-assembly.

38. CONNECT INLET HEATER WATER HOSE

*a

Protrusion

*b

Cutout

*c

Retainer

-

-

Push

Push in

(1) Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and push them together until the inlet heater water hose connector makes a "click" sound.

(2) Push in the retainer.

(3) Check that the flow shutting valve (water by-pass hose assembly) and inlet heater water hose connector are securely connected by pulling on them.

39. CONNECT OUTLET HEATER WATER HOSE

*a

Protrusion

*b

Cutout

*c

Retainer

-

-

Push

Push in

(1) Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater water hose connector and push them together until the outlet heater water hose connector makes a "click" sound.

(2) Push in the retainer.

(3) Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector are securely connected by pulling on them.

40. CONNECT NO. 1 FUEL VAPOR FEED HOSE

41. CONNECT NO. 1 VACUUM HOSE CONNECTOR

Click here

42. CONNECT NO. 2 RADIATOR HOSE

43. CONNECT NO. 1 RADIATOR HOSE

44. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

*a

N

-

-

(1) Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

NOTICE:

If the transmission control shaft lever is turned counterclockwise more than necessary, manual valve link lever sub-assembly may separate from the manual valve.

*1

Transmission Control Shaft Lever

*a

Manual Valve Link Lever Sub-assembly

*b

Manual Valve

*a

Correct

*b

Incorrect

(1) Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(2) Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

45. INSTALL BATTERY CLAMP SUB-ASSEMBLY

Torque:

15.4 N·m {157 kgf·cm, 11 ft·lbf}

46. CONNECT ENGINE WIRE

Torque:

Bolt (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut (B) :

7.6 N·m {77 kgf·cm, 67 in·lbf}

47. INSTALL ECM

Click here

48. INSTALL BATTERY

Click here

49. ADD TRANSFER OIL (for AWD)

Click here

50. ADD ENGINE OIL

Click here

51. ADD ENGINE COOLANT

Click here

52. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

Click here

53. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here

54. WARM UP ENGINE

Click here

55. INSPECT SHIFT LEVER POSITION

Click here

56. ADJUST SHIFT LEVER POSITION

Click here

57. INSPECT FOR ENGINE OIL LEAK

Click here

58. INSPECT FOR COOLANT LEAK

Click here

59. INSPECT FOR TRANSFER OIL LEAK (for AWD)

Click here

60. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK

61. INSPECT FOR REFRIGERANT LEAK

Click here

62. INSPECT FOR FUEL LEAK

Click here

63. INSPECT FOR EXHAUST GAS LEAK

Click here

64. CHECK ENGINE OIL LEVEL

Click here

65. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL

Click here

66. INSTALL FRONT BUMPER ASSEMBLY

Click here

67. INSTALL REAR ENGINE UNDER COVER LH

68. INSTALL REAR ENGINE UNDER COVER RH

69. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

70. INSTALL FRONT WHEELS

Click here

71. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here

72. PERFORM END POSITION INITIAL SETTING

Click here

73. PERFORM INITIALIZATION

Click here

74. INSPECT IGNITION TIMING

Click here

75. INSPECT ENGINE IDLE SPEED

Click here

76. INSPECT CO/HC

Click here

77. CHECK SPEED SENSOR SIGNAL

Click here

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