Toyota Corolla (E120) 2002–2008 Repair Manual / Exhaust / Removal & installation and disassembly & reassembly
Toyota Corolla (E120): Removal & installation and disassembly & reassembly
1. Remove oxygen sensor
- Remove a clip and tear off the floor mat.
- disconnect a oxygen sensor connector.
- Remove the oxygen sensor.
2. Remove tail pipe assy
- Remove 2 bolts, 2 springs and tail pipe assy.
3. Remove floor panel brace front
- Remove 2 nuts and the front floor panel brace front.
4. Remove exhaust pipe assy front
- Remove 2 bolts, 2 springs and exhaust pipe assy front.
5. Install exhaust pipe assy front
- using vernier calipers, measure the free length of the compression
spring.
Minimum length: 41.5 Mm (1.634 In.) Hint
: if the free length is less than minimum, replace the compression spring.
- install a new gasket on the exhaust manifold.
- install the exhaust pipe front with 2 bolts and 2 springs.
Torque: 43 nvm (440 Kgf·cm, 32 ft·lbf)
6. Install floor panel brace front
- install the front panel brace front with 2 nuts.
Torque: 30 nvm (302 Kgf·cm, 22 ft·lbf)
7. Install tail pipe assy
- using vernier calipers, measure the free length of the compression
spring.
Minimum length: 38.5 Mm (1.516 In.) Hint
: if the free length is less than minimum, replace the compression spring.
- install a new gasket on the exhaust pipe front.
- install the exhaust tail pipe with 2 bolts and 2 springs.
Torque: 43 nvm (440 Kgf·cm, 32 ft·lbf)
8. Install oxygen sensor
- Install the oxygen sensor to the exhaust pipe front.
Torque: 44 nvm (450 Kgf·cm, 33 ft·lbf)
- connect the oxygen sensor connector.
Hint
: after installing oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the oxygen sensor and reinstall it.
9. Check exhaust gas leak
Other materials:
Valve clearance
Adjustment
1. Remove cylinder head cover no.2
Remove the 2 nuts, 2 clips and cylinder head cover.
2. Disconnect engine wire
Remove the 5 clamps from the 5 clamp brackets.
Disconnect the 4 ignition coil connectors.
Remove the bolt and nut installing the engine wire ...
Inspection
1. Inspect front seat inner belt assy lh
When fastening the seat belt (buckle switch on).
Inspect the continuity and resistance between the
terminals.
Standard:
If the result is not as specified, replace the inner belt.
When releasing the seat belt (buckle switch ...
Do-it-yourself service precautions
If you perform maintenance
by yourself, be sure to follow
the correct procedure
as given in these sections.
Maintenance
WARNING
The engine compartment contains
many mechanisms and fluids that
may move suddenly, become hot,
or become electrically energized.
To avoid death or serious injury,
obser ...