Removal

2AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

CAUTION:
As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

NOTICE:
for Manual Transaxle:

When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

2. DISCHARGE FUEL SYSTEM PRESSURE Removal

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

5. REMOVE FRONT WHEEL

6. REMOVE CENTER ENGINE UNDER COVER

(a) Remove the 6 screws, 6 bolts and center engine under cover.

7. REMOVE NO. 1 ENGINE UNDER COVER

(a) Remove the 2 bolts, 7 clips and under cover.

8. DISCONNECT FRONT FENDER LINER RH

(a) Remove the screw and disconnect the front fender liner.

9. DISCONNECT FRONT FENDER LINER LH

(a) Remove the screw and disconnect the front fender liner.

10. REMOVE REAR ENGINE UNDER COVER RH Removal

11. REMOVE REAR ENGINE UNDER COVER LH

(a) Remove the 5 clips and under cover.

12. REMOVE NO. 2 ENGINE UNDER COVER

(a) Remove the 5 clips and under cover.

13. DRAIN ENGINE COOLANT Service and Repair

14. DRAIN ENGINE OIL Replacement

15. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) Service and Repair

16. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Replacement

17. DISCONNECT RADIATOR RESERVOIR ASSEMBLY

(a) Remove the 2 bolts and disconnect the radiator reservoir.

(b) Remove the grommet from the radiator reservoir.

18. REMOVE FAN AND GENERATOR V BELT Removal

19. REMOVE GENERATOR ASSEMBLY Removal

20. DISCONNECT NO. 2 RADIATOR HOSE Removal

21. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Removal

22. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Removal

23. REMOVE COOLER COMPRESSOR ASSEMBLY Removal

24. REMOVE RADIATOR HOSE CLAMP Removal

25. DISCONNECT NO. 1 RADIATOR HOSE Removal

26. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal

27. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Removal

28. REMOVE BATTERY CLAMP SUB-ASSEMBLY Removal

29. REMOVE BATTERY INSULATOR

30. REMOVE BATTERY

31. REMOVE BATTERY TRAY

32. REMOVE BATTERY CARRIER Removal

33. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the No. 1 fuel pipe clamp.

(b) Disconnect the fuel tube connector Fuel System: Precaution.

34. DISCONNECT HEATER WATER HOSE

(a) Disconnect the 2 heater water hoses.

35. DISCONNECT WIRE HARNESS AND HOSE

(a) Detach the clamp and disconnect the ECM connector.

(1) Raise the lever while pushing the lock on the lever and disconnect the ECM connector.

Text in Illustration

NOTICE:
After disconnecting the connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the connector.

(b) Remove the 2 nuts from the engine room No. 1 relay block.

(c) Disconnect the 3 connectors, detach the 2 clamps from the engine room No. 1 relay block and disconnect the wire harness.

(d) Remove the bolt and disconnect the wire harness.

(e) Disconnect the vacuum hose.

(f) Detach the clamp.

(g) Remove the bolt and disconnect the transmission wire.

(h) for Automatic Transaxle:

(1) Disconnect the 2 oil cooler hoses from the oil cooler tube.

36. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Remove the 4 clips and disconnect the 2 transmission control cables.

(b) Remove the bolt and disconnect the control cable support from the rear engine mounting insulator.

37. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Remove the nut and disconnect the control cable from the control shaft lever.

(b) Remove the clip and disconnect the transmission control cable from the control cable bracket.

(c) Remove the bolt and disconnect the control cable support from the rear engine mounting insulator.

38. DISCONNECT CLUTCH HOSE (for Manual Transaxle)

(a) Using a 10 mm union nut wrench, disconnect the clutch hose from the flexible hose tube.

(b) Remove the clip and disconnect the clutch hose.

39. SECURE STEERING WHEEL ASSEMBLY Removal

40. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

41. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

42. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal

43. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

44. REMOVE FRONT AXLE SHAFT NUT LH Removal

45. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Use the same procedure described for the LH side.

46. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH Removal

47. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

48. REMOVE FRONT AXLE ASSEMBLY LH

Removal

49. REMOVE FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

50. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

51. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING Disassembly

52. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

53. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and bracket.

54. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the flywheel housing under cover.

55. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transaxle) Removal

56. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

(a) Remove the 4 bolts and front suspension member reinforcement LH.

57. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

(a) Remove the 4 bolts and front suspension member reinforcement RH.

58. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Remove the 6 bolts and front crossmember.

59. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the bolt, nut and engine mounting insulator.

60. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set an engine lifter underneath the engine.

NOTICE:
Place the engine on wooden blocks or equivalent so that the engine is level.

(b) Remove the bolt and 2 nuts and disconnect the engine mounting insulator RH.

(d) Remove the 6 bolts and front suspension member rear brace RH and LH.

(e) Remove the 2 bolts and front suspension crossmember.

(f) Operate the engine lifter and slowly remove the engine from the vehicle.

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

61. INSTALL ENGINE HANGER

(a) Install 2 engine hangers with 2 bolts as shown in the illustration.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

Text in Illustration

HINT

(b) Attach an engine sling device and hang the engine with a chain block.

62. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Remove the bolt and front suspension crossmember from the engine with transaxle.

NOTICE:
Do not damage any engine or transaxle components.

HINT
Raise the engine with transaxle assembly while keeping it level.

63. REMOVE STARTER ASSEMBLY Removal

64. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

Removal

65. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

Removal

66. FIX ENGINE ASSEMBLY

(a) Using wooden blocks or plate lift attachments, set the engine on a flat surface.

NOTICE:
* Place wooden blocks or plate lift attachments so that the engine is level.
* Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
* Perform this step while supporting the engine assembly using a sling device and chain block.

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

68. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

69. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

Removal

70. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Removal

71. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Removal

72. REMOVE ENGINE WIRE

(a) Remove the engine wire from the engine.

73. INSTALL ENGINE TO ENGINE STAND

NOTICE:
* Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

(a) Install the engine to an engine stand with the bolts.

(b) Remove the 2 bolts and 2 engine hangers.

74. REMOVE REAR ENGINE MOUNTING INSULATOR

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

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

75. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(a) Detach the 3 cooler pipe clamps.

(b) Remove the 2 bolts, nut and 2 cooler pipe brackets.

(c) Remove the 3 bolts and engine mounting insulator.

76. REMOVE ENGINE MOUNTING SPACER

HINT
Perform this procedure only when replacement of the engine mounting spacer is necessary.

(a) Remove the 2 bolts and engine mounting spacer.

77. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(a) Remove the 4 bolts and engine mounting insulator.