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

  1. Remove a clip and tear off the floor mat.
  2.  disconnect a oxygen sensor connector.

  1. Remove the oxygen sensor.

2. Remove tail pipe assy

  1. Remove 2 bolts, 2 springs and tail pipe assy.

3. Remove floor panel brace front

  1. Remove 2 nuts and the front floor panel brace front.

4. Remove exhaust pipe assy front

  1. Remove 2 bolts, 2 springs and exhaust pipe assy front.

5. Install exhaust pipe assy front

  1.  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.

  2.  install a new gasket on the exhaust manifold.
  3.  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

  1.  install the front panel brace front with 2 nuts.

    Torque: 30 nvm (302 Kgf·cm, 22 ft·lbf)

7. Install tail pipe assy

  1.  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.

  2.  install a new gasket on the exhaust pipe front.
  3.  install the exhaust tail pipe with 2 bolts and 2 springs.

    Torque: 43 nvm (440 Kgf·cm, 32 ft·lbf)

8. Install oxygen sensor

  1. Install the oxygen sensor to the exhaust pipe front.

    Torque: 44 nvm (450 Kgf·cm, 33 ft·lbf)

  2.  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

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    Precaution
    Caution: the corolla is equipped with srs, which comprises a driver airbag, front passenger airbag and side airbag. Failure to carry out service operations in the correct sequence could cause the srs to unexpectedly deploy during servicing, possibly leading to a serious accident. Fu ...

    Body
    On–vehicle inspection 1. Canada: tighten bolts and nuts on chassis and body  tighten the bolts and nuts on the chassis parts listed below, if necessary Front axle and suspension drive train rear axle and suspension brake system engine mounting other chassis parts ...

    Pre–check
    1. Srs warning light check Turn the ignition switch to the on position and check that the srs warning light lights up. check that the srs warning light goes out after approx. 6 Seconds. Hint: when the ignition switch is at on and the srs warning light remains on or flashes, the ...