Removal

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM Removal

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE BATTERY
(a) Loosen the 2 nuts and remove the battery clamp.
4. REMOVE BATTERY TRAY
5. REMOVE FRONT WHEEL
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE FRONT FENDER APRON SEAL RH Removal

9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY Removal

10. DRAIN ENGINE COOLANT Testing and Inspection

11. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Removal

12. DRAIN TRANSAXLE OIL (for Manual Transaxle) Removal

13. DISCONNECT RADIATOR HOSE INLET
14. DISCONNECT RADIATOR HOSE OUTLET
15. DISCONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)
16. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)
17. REMOVE RADIATOR ASSEMBLY Removal

18. REMOVE AIR CLEANER ASSEMBLY
(a) Remove the air cleaner cap and element Removal.
(b) Remove the clamp of the engine wire.






(c) Remove the 3 bolts from the air cleaner case.
(d) Disconnect the air cleaner case from the No. 1 air cleaner inlet.
19. REMOVE BATTERY CARRIER






(a) Disconnect the clamp of the engine wire.
(b) Remove the 4 bolts and battery carrier.
20. DISCONNECT FUEL MAIN TUBE Removal

21. DISCONNECT UNION TO CONNECTOR TUBE HOSE






(a) Disconnect the union to connector tube hose from the booster vacuum tube.
22. DISCONNECT HEATER WATER INLET HOSE






(a) Disconnect the heater water inlet hose from the booster vacuum tube.
23. DISCONNECT HEATER WATER OUTLET HOSE






(a) Disconnect the heater water outlet hose from the air conditioner tube.
24. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Removal

25. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Removal

26. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Removal

27. REMOVE FAN AND GENERATOR V BELT Removal

28. REMOVE GENERATOR ASSEMBLY Removal

29. REMOVE COOLER COMPRESSOR ASSEMBLY
HINT: Disconnect the compressor together with the low-pressure and high-pressure hoses, then secure it to the vehicle side using rope.

30. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY Removal

31. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junction block.
(b) Pull out the engine wire.
(c) Remove the engine room relay block cover.






(d) Remove the 2 claws and 2 connectors, and push the engine wire harness up.






(e) Remove the 2 clamps of the engine wire.






(f) Remove the nut from the battery positive (+) terminal to disconnect the engine wire.






(g) Remove the bolt and ground cable.
32. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

33. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

34. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

35. REMOVE FRONT AXLE HUB NUT Removal

36. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH Removal

37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH Removal

38. DISCONNECT FRONT SPEED SENSOR LH Removal

39. DISCONNECT FRONT SPEED SENSOR RH Removal

40. SEPARATE TIE ROD END LH SUB-ASSEMBLY Removal

41. REMOVE TIE ROD END RH SUB-ASSEMBLY Removal

42. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH Removal

43. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER RH Removal

44. REMOVE FRONT AXLE HUB LH SUB-ASSEMBLY Removal

45. REMOVE FRONT AXLE HUB RH SUB-ASSEMBLY Removal

46. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE






(a) Disconnect the No. 1 pump hose.






(b) Disconnect the return tube.
(c) Set the engine lifter.






(d) Remove the 2 bolts, 2 nuts and engine mounting insulator RH.






(e) Remove the through bolt, nut and engine mounting insulator LH.






(f) Remove the 8 bolts and front suspension member brace rear RH and LH.






(g) Remove the 2 bolts and 2 nuts shown in the illustration.
(h) Carefully remove the engine with transaxle from the vehicle.






(i) Install the No. 1 and No. 2 engine hangers with the bolts as shown in the illustration.
Parts No.:






Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)
(j) Attach the sling device and the engine with the chain block.
47. REMOVE VANE PUMP ASSEMBLY
48. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER






(a) Remove the through bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.






(b) Remove the through bolt and engine mounting insulator RR from the engine mounting bracket RR.
(c) Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
49. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

50. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

51. REMOVE STARTER ASSEMBLY Removal

52. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Removal

53. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle)
54. REMOVE DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle)






(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021






(b) Remove the 8 bolts, rear spacer, drive plate and front spacer.
55. REMOVE MANUAL TRANSAXLE ASSEMBLY Removal

56. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) Removal

57. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) Removal

58. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)






(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021






(b) Remove the 8 bolts and flywheel.
59. REMOVE DRIVE SHAFT BEARING BRACKET






(a) Remove the 3 bolts and drive shaft bearing bracket.
60. REMOVE OIL DIPSTICK
61. REMOVE OIL DIPSTICK GUIDE Removal

62. REMOVE MANIFOLD STAY Removal

63. REMOVE NO. 2 MANIFOLD STAY Removal

64. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal

65. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Removal

66. REMOVE WATER INLET Removal

67. REMOVE THERMOSTAT
68. REMOVE NO. 1 WATER BY-PASS PIPE






(a) Remove the bolt, 2 nuts and water by-pass pipe.
(b) Remove the gasket from the cylinder block.
69. REMOVE INTAKE MANIFOLD ASSEMBLY Removal

70. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR Removal

71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal

72. REMOVE IGNITION COIL ASSEMBLY Removal

73. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal

74. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal

75. REMOVE KNOCK SENSOR Removal

76. REMOVE RADIO SETTING CONDENSER






(a) Remove the bolt and condenser.
77. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
78. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Removal

79. REPLACE PARTIAL ENGINE ASSEMBLY