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.

3. 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