FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Scion >> 2009 >> xB L4-2.4L (2AZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Installation

Installation








2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Installation
2. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Installation
3. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) Installation
4. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation
5. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation
6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) Installation
7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) Installation
8. INSTALL DRIVE SHAFT BEARING BRACKET





(a) Install the bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)





9. INSTALL REAR ENGINE MOUNTING INSULATOR SUB-ASSEMBLY
(a) Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)





10. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
(b) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator RH and LH can be installed.
CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:
- Make sure that the engine is clear of all wiring and hoses.
- While raising the engine into the vehicle, do not allow it to contact the vehicle.

11. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH





(a) Install the engine mounting insulator LH with the 4 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
(b) Install the engine mounting insulator LH with the through bolt and nut.
HINT: Install the through bolt by tightening the nut.

Torque: 56 Nm (571 kgf-cm, 41 ft-lbf)
12. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Installation
13. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY





(a) Install the front crossmember with the 4 bolts.
Torque: 96 Nm (979 kgf-cm, 71 ft-lbf)





(b) Install the front engine mounting insulator with the 2 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
HINT: Only perform this procedure when replacement of the engine mounting insulator in necessary.





(c) Install the engine mounting insulator front to the engine mounting bracket front with the bolt and nut.
Torque: 145 Nm (1479 kgf-cm, 107 ft-lbf)
14. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Support the front suspension crossmember with a transmission jack.
(b) While inserting SST into the reference holes on the front suspension crossmember RH and LH alternately, tighten 2 bolts A, 2 bolts B, and 2 nuts on the RH and LH sides to the respective specified torque in several steps.





SST: 09670-00020
Bolt A - Torque: 145 Nm (1479 kgf-cm, 107 ft-lbf)
Bolt B - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
15. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH





(a) Install the front suspension member rear brace LH with the 3 bolts.
Bolt A - Torque: 145 Nm (1479 kgf-cm, 107 ft-lbf)
Bolt B - Torque: 93 Nm (948 kgf-cm, 69 ft-lbf)
16. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
HINT: Perform the same procedure for the LH side.

17. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH





(a) Install the front suspension member reinforcement LH with the 4 bolts.
Torque: 96 Nm (979 kgf-cm, 71 ft-lbf)
NOTICE: Temporarily tighten bolts A and B, and then fully tighten the 4 bolts in the order of C, B, D, and A.

18. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
HINT: Perform the same procedure for the LH side.

19. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle) Installation
20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
22. INSTALL FRONT AXLE ASSEMBLY LH Installation
23. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

24. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
25. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

26. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation
27. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation
29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

30. INSTALL FRONT SPEED SENSOR LH Installation
31. INSTALL FRONT SPEED SENSOR RH
HINT: Perform the same procedure for the LH side.

32. INSTALL FRONT AXLE HUB NUT LH Installation
33. INSTALL FRONT AXLE HUB NUT RH
HINT: Perform the same procedure for the LH side.

34. CONNECT ENGINE WIRE
(a) Install the ground cable with the bolt located near the starter.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(b) Connect the ground cable to the clamp located near the starter.
(c) Connect the ground cable connector.





(d) Connect the engine wire to the positive battery terminal with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)





(e) Connect the 2 engine wire connectors and install the nut.
(f) Install the engine room relay block cover.
(g) Attach the clamp of the engine wire cover.
(h) Install the engine wire cover to with the bolt.
35. CONNECT ECM





(a) Connect the connector to the engine control computer with the clamp and lock lever.
36. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation
37. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
38. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
39. INSTALL STARTER ASSEMBLY (for Automatic Transaxle) Installation
40. INSTALL STARTER ASSEMBLY (for Manual Transaxle) Installation
41. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Installation
42. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Installation
43. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle) Installation
44. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
Installation
45. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle)
Refer to the procedures under "INSTALL CLUTCH ACCUMULATOR ASSEMBLY" Installation
46. CONNECT CHECK VALVE TO CONNECTOR TUBE HOSE





(a) Connect the check valve to connector tube hose.
47. INSTALL FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube connector and fuel pipe.
CAUTION: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.





(b) Engage the claw and install the No. 1 fuel pipe clamp.
(c) Install the No. 2 fuel pipe clamp.
48. CONNECT HEATER INLET WATER HOSE Installation
49. CONNECT HEATER OUTLET WATER HOSE Installation
50. CONNECT NO. 2 OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle)
51. CONNECT NO. 1 OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle)
52. INSTALL COMPRESSOR ASSEMBLY Installation
53. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation
54. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation
55. INSTALL GENERATOR ASSEMBLY Installation
56. INSTALL FAN & GENERATOR V BELT Installation
57. INSTALL THROTTLE BODY ASSEMBLY Installation
58. INSTALL NO. 2 BATTERY CARRIER Installation
59. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
60. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Installation
61. INSTALL RADIATOR RESERVE TANK ASSEMBLY Installation
62. INSTALL FRONT EXHAUST PIPE ASSEMBLY





(a) Using vernier calipers, measure the free length of the compression spring.
Minimum length:
41.5 mm (1.634 in.)
If the length is not as specified, replace the compression spring.
(b) Install the new exhaust pipe gasket to the exhaust manifold converter.
(c) Install the front exhaust pipe with the 2 compression springs and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
63. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Install the new gasket onto the front exhaust pipe.
(b) Install the center exhaust pipe with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
64. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Installation
65. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Procedures
66. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)
67. INSPECT AND ADJUST MANUAL TRANSAXLE OIL (for Manual Transaxle) Testing and Inspection
68. INSTALL BATTERY Installation
69. ADD ENGINE COOLANT Service and Repair
70. CHARGE REFRIGERANT Service and Repair
71. WARM UP ENGINE Service and Repair
72. ADD CLUTCH FLUID (for Manual Transaxle)
73. BLEED CLUTCH LINE (for Manual Transaxle) Procedures
74. INSPECT FOR CLUTCH FLUID LEAK (for Manual Transaxle)
75. INSPECT CLUTCH FLUID LEVEL IN RESERVOIR (for Manual Transaxle)
76. INSPECT FOR FUEL LEAK Installation
77. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection
78. INSPECT REFRIGERANT LEAK Service and Repair
79. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK (for Automatic Transaxle)
80. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle) On-Vehicle Inspection
81. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle) Installation
82. INSPECT EXHAUST GAS LEAK
83. INSTALL REAR ENGINE UNDER COVER LH
84. INSTALL REAR ENGINE UNDER COVER RH
85. INSTALL NO. 2 ENGINE UNDER COVER
86. INSTALL NO. 1 ENGINE UNDER COVER
87. INSTALL CENTER TRANSMISSION UNDER COVER ASSEMBLY
88. INSTALL FRONT WHEELS
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)
89. INSTALL HOOD Installation
90. INSPECT HOOD Adjustments
91. ADJUST HOOD Adjustments
92. INSPECT ENGINE IDLING SPEED Engine
93. INSPECT CO/HC Engine
94. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
95. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment Front Wheel Alignment.
96. INSPECT ABS SPEED SENSOR SIGNAL
pro multis Credits:Operation CHARM About Operation CHARM