Toyota Corolla Cross: Removal

REMOVAL

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	DRIVE SHAFT BEARING BRACKET	43457	-	-	-
2	V-RIBBED BELT TENSIONER ASSEMBLY	16620D	-	-	-
3	NO. 2 RADIATOR HOSE	16572D	-	-	-
4	NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY	16207	-	-	-
5	FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)	16260		-	-
6	WATER HOSE CLAMP BRACKET	16575B	-	-	-
7	NO. 1 EXHAUST MANIFOLD HEAT INSULATOR	17167		-	-
8	EXHAUST MANIFOLD (TWC: Front Catalyst)	17141		-	-

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Non-reusable part

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Procedure		Part Name Code
9	DISCONNECT NO. 8 WATER BY-PASS HOSE	16296	-	-	-
10	THROTTLE BODY WITH MOTOR ASSEMBLY	22030		-	-
11	NO. 5 WATER BY-PASS HOSE	16282		-	-
12	THROTTLE BODY GASKET	22271	-	-	-
13	SEPARATE NO. 3 WATER BY-PASS HOSE	16267	-	-	-
14	SEPARATE NO. 4 WATER BY-PASS HOSE	16281	-	-	-
15	WIRE HARNESS CLAMP BRACKET	-	-	-	-
16	EGR COOLER ASSEMBLY	25680	-	-	-
17	EGR VALVE GASKET	25627	-	-	-
18	NO. 1 EGR COOLER GASKET	25685	-	-	-
19	NO. 1 EGR PIPE SUB-ASSEMBLY	25601		-	-
20	EGR VALVE ADAPTER GASKET	25629	-	-	-
21	EGR INLET GASKET	25628	-	-	-
22	REMOVE NO. 4 WATER BY-PASS HOSE	16281	-	-	-
23	REMOVE NO. 8 WATER BY-PASS HOSE	16296	-	-	-
24	EGR VALVE ASSEMBLY	25620		-	-
25	REMOVE NO. 3 WATER BY-PASS PIPE	16279		-	-
26	INTAKE MANIFOLD STAY	17138B		-	-
27	NO. 1 FUEL VAPOR FEED HOSE	23826	-	-	-
28	INTAKE MANIFOLD	17111		-	-

*A	Type A	*B	Type B
●	Non-reusable part	-	-

Procedure		Part Name Code
29	FUEL TUBE SUB-ASSEMBLY	23910A		-	-
30	NO. 1 FUEL PIPE SUB-ASSEMBLY	23801P		-	-
31	FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)	23100X		-	-
32	FUEL PUMP FLANGE	23191	-	-	-
33	FUEL PUMP SPACER GASKET	23224D	-	-	-
34	FUEL PUMP LIFTER ASSY	23470	-	-	-
35	NO. 1 WATER BY-PASS HOSE ASSEMBLY	-	-	-	-
36	SENSOR WIRE	82219C	-	-	-
37	NO. 6 ENGINE WIRE	82126A	-	-	-

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Non-reusable part

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Procedure		Part Name Code
38	FUEL DELIVERY PIPE SUB-ASSEMBLY	23807		-	-
39	FUEL DELIVERY SPACER	23891	-	-	-
40	INJECTOR VIBRATION INSULATOR	23291	-	-	-
41	NO. 5 ENGINE WIRE	82125N	-	-	-
42	PORT FUEL INJECTOR ASSEMBLY	23250F		-	-
43	FUEL DELIVERY PIPE	23814B		-	-
44	DIRECT FUEL INJECTOR ASSEMBLY	23250E		-	-
45	NOZZLE HOLDER CLAMP	23695A	-	-	-
46	NO. 3 FUEL INJECTOR BACK-UP RING	23258		-	-
47	NO. 1 FUEL INJECTOR BACK-UP RING	23256	-	-	-
48	C-RING	-	-	-	-
49	INJECTOR VIBRATION INSULATOR	23291A	-	-	-
50	FUEL INJECTOR SEAL	23255A		-	-

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Non-reusable part

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Procedure		Part Name Code
51	IGNITION COIL ASSEMBLY	19500		-	-
52	ENGINE OIL LEVEL DIPSTICK GUIDE	11452D	-	-	-
53	WATER INLET WITH THERMOSTAT SUB-ASSEMBLY	16031	-	-	-
54	ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)	16032		-	-
55	NO. 3 EXHAUST MANIFOLD HEAT INSULATOR	17169A	-	-	-
56	PURGE VALVE (PURGE VSV)	25860	-	-	-
57	VACUUM SURGE TANK	25719	-	-	-
58	VACUUM SURGE TANK BRACKET	25759A	-	-	-
59	NO. 2 VENTILATION HOSE	12262	-	-	-
60	WIRE HARNESS CLAMP BRACKET	-		-	-
61	STUD BOLT	-		-	-

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Non-reusable part

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CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during engine unit 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 port fuel injector assembly Replacement of direct fuel injector assembly Replacement of fuel pump assembly (for high pressure side) Replacement of ignition coil assembly	Inspection After Repair	Poor idle, etc. Engine start function, etc.

NOTICE:

This procedure includes the removal 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. REMOVE DRIVE SHAFT BEARING BRACKET (for AWD)

2. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE: Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc. Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

3. REMOVE NO. 2 RADIATOR HOSE

4. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

5. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(1) Remove the bolt to disconnect the flow shutting valve (water by-pass hose assembly) from the water hose clamp bracket.

(2) Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.

HINT:

Use a container to catch any engine coolant which flows out of the flow shutting valve (water by-pass hose assembly) and water by-pass outlet sub-assembly.

6. REMOVE WATER HOSE CLAMP BRACKET

7. REMOVE REMOVE NO.1 EXHAUST MANIFOLD HEAT INSULATOR

for 2WD: for AWD:

8. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

for 2WD: for AWD:

9. DISCONNECT NO. 8 WATER BY-PASS HOSE

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10. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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11. DISCONNECT NO. 5 WATER BY-PASS HOSE

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12. REMOVE THROTTLE BODY GASKET

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13. SEPARATE NO. 3 WATER BY-PASS HOSE

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14. SEPARATE NO. 4 WATER BY-PASS HOSE

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15. REMOVE WIRE HARNESS CLAMP BRACKET

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16. REMOVE EGR COOLER ASSEMBLY

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17. REMOVE EGR VALVE GASKET

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18. REMOVE NO. 1 EGR COOLER GASKET

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19. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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20. REMOVE EGR VALVE ADAPTER GASKET

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21. REMOVE EGR INLET GASKET

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22. REMOVE NO. 4 WATER BY-PASS HOSE

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23. REMOVE NO. 8 WATER BY-PASS HOSE

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24. REMOVE EGR VALVE ASSEMBLY

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25. REMOVE NO. 3 WATER BY-PASS PIPE

(1) Using an 8 mm socket wrench, remove the bolt and disconnect the No. 3 water by-pass pipe from the intake manifold.

(2) Slide the clip and remove the No. 3 water by-pass pipe from the water outlet.

26. REMOVE INTAKE MANIFOLD STAY

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27. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

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28. REMOVE INTAKE MANIFOLD

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29. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(1) Disconnect the fuel tube sub-assembly from the fuel pump assembly.

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(2) Remove the fuel pipe clamp from the fuel tube connector.

(3) Disconnect the fuel tube sub-assembly from the fuel delivery pipe.

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30. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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31. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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32. REMOVE FUEL PUMP FLANGE

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33. REMOVE FUEL PUMP SPACER GASKET

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34. REMOVE FUEL PUMP LIFTER ASSY

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35. REMOVE NO. 1 WATER BY-PASS HOSE ASSEMBLY

36. REMOVE SENSOR WIRE

37. REMOVE NO. 6 ENGINE WIRE

38. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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39. REMOVE FUEL DELIVERY SPACER

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40. REMOVE INJECTOR VIBRATION INSULATOR

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41. REMOVE NO. 5 ENGINE WIRE

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42. REMOVE PORT FUEL INJECTOR ASSEMBLY

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43. REMOVE FUEL DELIVERY PIPE

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44. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

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45. REMOVE NOZZLE HOLDER CLAMP

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46. REMOVE NO. 3 FUEL INJECTOR BACK-UP RING

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47. REMOVE NO. 1 FUEL INJECTOR BACK-UP RING

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48. REMOVE C-RING

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49. REMOVE INJECTOR VIBRATION INSULATOR

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50. REMOVE FUEL INJECTOR SEAL

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51. REMOVE IGNITION COIL ASSEMBLY

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52. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

*1

OIL LEVEL GAGE SUB-ASSEMBLY

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53. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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54. REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

55. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

56. REMOVE PURGE VALVE (PURGE VSV)

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57. REMOVE VACUUM SURGE TANK

58. REMOVE VACUUM SURGE TANK BRACKET

59. REMOVE NO. 2 VENTILATION HOSE

60. REMOVE WIRE HARNESS CLAMP BRACKET

(1) Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.

(2) Remove the bolt and wire harness clamp bracket from the camshaft housing sub-assembly.

61. REMOVE STUD BOLT

(1) Using an E8 "TORX" socket wrench, remove the stud bolt from the timing chain cover assembly.

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