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Home >> Scion >> 2004 >> xB L4-1.5L (1NZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Installation >> Part 2

Part 2

REPLACEMENT





51. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using SST, remove the engine coolant temperature sensor.
SST 09817-33190





52. REMOVE KNOCK SENSOR
a. Using SST, remove the knock sensor.
SST 09816-30010
53. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Using SST, remove the oil pressure switch.
SST 09268-06021
54. REPLACE PARTIAL ENGINE ASSY
55. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, install the oil pressure switch.
SST 09268-46021
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)

NOTICE: Do not start the engine within 1 hour of installation.





56. INSTALL KNOCK SENSOR
a. Using SST, install the knock sensor
SST 09816-30010
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)





57. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket to the engine coolant temperature sensor.
b. Using SST, fix the engine coolant temperature sensor.
SST 09817-33190
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
58. INSTALL WATER BY-PASS PIPE NO.1
a. Install a new gasket and the water by-pass pipe with the 2 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in. lbs.)
59. INSTALL IGNITION COIL NO.1
Torque: 9.0 Nm (92 kgf-cm, 80 in. lbs.)





60. INSTALL EXHAUST MANIFOLD
a. Using several steps, install a new exhaust manifold gasket and the exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 in. lbs.)
61. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the exhaust manifold heat insulator No.1 with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in. lbs.)
62. INSTALL MANIFOLD SUPPORT BRACKET
a. Install the manifold support bracket with the 3 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
63. INSTALL BOOSTER VACUUM TUBE
a. Install the booster vacuum tube with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in. lbs.)





64. INSTALL INTAKE MANIFOLD
a. Install a new gasket to the intake manifold.
b. Install the intake manifold with the 3 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
65. INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL
SST 09213-58012 (91111-50845), 09330-00021
66. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)
67. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)
68. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
69. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
70. INSTALL GENERATOR ASSY
71. INSTALL STARTER ASSY





72. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
a. Fasten the bolt to secure the engine and transaxle assembly to the suspension crossmember.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)





73. INSTALL VANE PUMP ASSY
a. Install the vane pump assembly with the 2 bolts.
Torque: 44 Nm (449 kgf-cm, 33 ft. lbs.)

HINT: After adjusting the V-ribbed belt, first tighten bolt A, then tighten bolt B.

74. INSTALL VANE PUMP V BELT
a. Temporarily install the V-ribbed belt on each pulley.
75. ADJUST VANE PUMP V BELT





76. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine with the transaxle on the engine lifter.
b. Install the engine with the transaxle to the engine compartment.
c. Temporarily install the suspension crossmember with the 8 bolts.





d. Install the engine mounting bracket LH to the engine mounting insulator LH with the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





e. Install the engine mounting insulator RH with the 5 bolts and nut.
Torque:
Bolt A 45 Nm (459 kgf-cm, 33 ft. lbs.)
Bolt B 52 Nm (530 kgf-cm, 38 ft. lbs.)
Nut 52 Nm (530 kgf-cm, 38 ft. lbs.)
f. Install the liquid tube with the bolt.
Torque:
Bolt C 9.8 Nm (100 kgf-cm, 7.2 ft. lbs.)





g. Insert SST to the positioning holes of the right hand crossmember and vehicle.
SST 09670-00010
h. Temporarily tighten bolt A, then tighten bolt B.





i. Insert SST to the positioning holes of the left-hand crossmember and vehicle.
SST 09670-00010
j. Temporarily tighten bolt A, then tighten bolt B.
k. Insert SST to the positioning holes of the right-hand crossmember and vehicle again, then tighten the bolts to the specified torque.
SST 09670-00010
Torque:
Bolt A 116 Nm (1,183 kgf-cm, 86 ft. lbs.)
Bolt B 70 Nm (714 kgf-cm, 52 ft. lbs.)
l. Insert SST to the positioning holes of the left-handle crossmember and vehicle again, then tighten the bolts to the specified torque.
SST 09670-00010
Torque:
Bolt A 116 Nm (1,183 kgf-cm, 86 ft. lbs.)
Bolt B 70 Nm (14 kgf-cm, 52 ft. lbs.)





m. Tighten the 4 bolts shown in the illustration.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
77. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Install the front suspension arm lower to the steering knuckle with the nut.
Torque: 98 Nm (999 kgf-cm, 72 ft. lbs.)
b. Install a new clip.

HINT: Perform the same procedure as above on the opposite side.

78. INSTALL TIE ROD END SUB-ASSY LH
a. Connect the tie rod end to the steering knuckle with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Install a new cotter pin.

NOTICE:
^ Be careful of the threads and tapered portions of the tie rod end not to make contact with oils.
^ After tightening the castle nut, turn it clockwise within 60° to align the pin holes for the cotter pin.

HINT: Perform the same procedure as above on the opposite side.

79. CONNECT SPEED SENSOR FRONT LH (W/ ABS)
a. Install the speed sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in. lbs.)

HINT: Perform the same Procedure as above on the opposite side.





80. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install the new hub nut.
Torque: 216 Nm (2,203 kgf-cm, 160 ft. lbs.)
b. Using a chisel, stake the hub nut.

HINT: Perform the same procedure as above on the opposite side.

81. INSTALL SHAFT ASSY, STEERING INTERMEDIATE
82. INSTALL EXHAUST PIPE ASSY FRONT
83. INSTALL FLOOR PANEL BRACE FRONT
84. INSTALL A/C COMPRESSOR
85. INSTALL FAN AND GENERATOR V BELT
a. Temporarily install the V-ribbed belt on each pulley.
86. ADJUST FAN AND GENERATOR V BELT
87. INSTALL RADIATOR ASSY
88. CONNECT FUEL TUBE SUB-ASSY
89. INSTALL AIR CLEANER ASSY





90. INSTALL CYLINDER HEAD COVER NO.2
a. First tighten nut A, then tighten bolt B.
Torque: 7.0 Nm (71 kgf-cm, 62 in. lbs.)
91. INSTALL FRONT BUMPER COVER
92. INSTALL ENGINE UNDER COVER LH
Torque:
5.0 Nm (51 kgf-cm, 44 in. lbs.) for Bolt
5.0 Nm (51 kgf-cm, 44 in. lbs.) for Nut
93. INSTALL ENGINE UNDER COVER RH
Torque:
5.0 Nm (51 kgf-cm, 44 in. lbs.) for Bolt
5.0 Nm (51 kgf-cm, 44 in. lbs.) for Nut
94. ADD ENGINE OIL
95. ADD ENGINE COOLANT
96. CHECK FOR ENGINE OIL LEAKS
97. CHECK FOR ENGINE COOLANT LEAKS
98. CHECK FOR FUEL LEAKS
99. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
100. CHECK IDLE SPEED AND IGNITION TIMING
101. INSPECT CO/HC
102. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS)

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