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Removal





2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

2. SECURE STEERING WHEEL Removal

3. REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

4. DISCHARGE FUEL SYSTEM PRESSURE Removal

5. REMOVE BATTERY Removal

6. REMOVE HOOD Removal

7. REMOVE FRONT WHEELS

8. REMOVE CENTER TRANSMISSION UNDER COVER ASSEMBLY

9. REMOVE NO. 1 ENGINE UNDER COVER

10. REMOVE NO. 2 ENGINE UNDER COVER

11. REMOVE REAR ENGINE UNDER COVER LH

12. REMOVE REAR ENGINE UNDER COVER RH

13. SEPARATE CENTER EXHAUST PIPE ASSEMBLY

(a) Remove the 2 bolts and separate the center exhaust pipe.

(b) Remove the gasket.

14. REMOVE FRONT EXHAUST PIPE ASSEMBLY

(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 2 bolts and 2 compression springs and remove the front exhaust pipe.

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

16. DRAIN ENGINE COOLANT Service and Repair

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

18. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) Removal

19. SEPARATE RADIATOR RESERVE TANK ASSEMBLY Removal

20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE Removal

21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Removal

22. REMOVE NO. 2 BATTERY CARRIER Removal

23. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY Removal

24. REMOVE FAN AND GENERATOR V BELT Removal

25. REMOVE GENERATOR ASSEMBLY Removal

26. SEPARATE SUCTION HOSE SUB-ASSEMBLY Removal

27. SEPARATE DISCHARGE HOSE SUB-ASSEMBLY Removal

28. REMOVE COMPRESSOR ASSEMBLY Removal

29. DISCONNECT OUTLET RADIATOR HOSE





(a) Disconnect the outlet radiator hose.

30. DISCONNECT INLET RADIATOR HOSE





(a) Disengage the heated oxygen sensor wire harness clamp.

(b) Disconnect the inlet radiator hose.

31. DISCONNECT NO. 1 OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Removal

32. DISCONNECT BREATHER HOSE (for Automatic Transaxle)





(a) Disengage the clamp and disconnect the breather hose.

33. DISCONNECT OUTLET HEATER WATER HOSE





(a) Disconnect the outlet heater water hose.

34. DISCONNECT INLET HEATER WATER HOSE





(a) Disconnect the inlet heater water hose.

35. REMOVE FUEL TUBE SUB-ASSEMBLY





NOTICE:
Do not forcibly bend, kink or twist the fuel main tube.

(a) Remove the fuel tube from the fuel hose clamp.

(b) Remove the No. 2 fuel pipe clamp.

(c) Wipe off any dirt on the fuel tube connector.

(d) Hold the fuel tube connector, and then install SST.

SST : 09268-21010

(e) Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.

(f) Insert SST into the fuel tube and hold it. Then push the fuel tube connector toward SST.

(g) Mount the retainer of the fuel tube connector onto the chamfered part of SST.

(h) Slide SST and the fuel tube connector together towards the fuel tube until they make a "click" sound, and then disconnect the fuel tube.





(i) Drain the fuel remaining inside the fuel tube.

(j) Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected part.

(k) Release the claw and remove the No. 1 fuel pipe clamp.





(l) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.





NOTICE:
* Remove any dirt and foreign matter from the fuel tube connector before performing this work.
* Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
* Perform this work by hand. Do not use any tools.
* Do not forcibly bend, kink or twist the nylon tube.
* Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
* If the fuel tube connector and pipe are stuck, push and pull to release them.

36. DISCONNECT CHECK VALVE TO CONNECTOR TUBE HOSE

(a) Disconnect the check valve to connector tube hose.





37. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle)

Refer to the procedures under "REMOVE CLUTCH ACCUMULATOR ASSEMBLY". Removal

38. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)

Removal

39. SEPARATE ACCUMULATOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle) Removal

40. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Removal

41. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Removal

42. REMOVE STARTER ASSEMBLY (for Automatic Transaxle) Removal

43. REMOVE STARTER ASSEMBLY (for Manual Transaxle) Removal

44. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

45. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

46. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal

47. SEPARATE ECM

(a) Pull up the lever and disconnect the ECM connector.





48. SEPARATE ENGINE WIRE

(a) Remove the engine room relay block cover.





(b) Remove the nut and disconnect the 2 engine wire connectors.

(c) Remove the bolt and engine wire cover. Then disconnect the engine wire from the engine wire cover.





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

(e) Disconnect the ground cable connector.

(f) Disconnect the ground cable from the clamp located near the starter.

(g) Remove the bolt and ground cable located near the starter.

49. REMOVE FRONT AXLE HUB NUT LH Removal

50. REMOVE FRONT AXLE HUB NUT RH

HINT
Perform the same procedure for the LH side.

51. SEPARATE FRONT SPEED SENSOR LH Removal

52. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure for the LH side.

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

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

HINT
Perform the same procedure for the LH side.

55. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

56. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

57. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

58. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

59. SEPARATE FRONT AXLE ASSEMBLY LH Removal

60. SEPARATE FRONT AXLE ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

61. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

62. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

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

64. SUSPEND ENGINE ASSEMBLY

(a) Install the No. 1 and No. 2 engine hangers with the new bolts as shown in the illustration.





Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

Part No.









(b) Attach the sling device to the engine hangers and chain block.

65. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH





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

66. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

HINT
Perform the same procedure for the LH side.

67. REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH

(a) Remove the 3 bolts and front suspension member rear brace LH.





68. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH

HINT
Perform the same procedure for the LH side.

69. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Support the front suspension crossmember with a transmission jack.

(b) Remove the 4 bolts, 2 nuts, and front suspension crossmember sub-assembly.





70. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY

(a) Remove the bolt and nut.





(b) Separate the engine mounting insulator front from the engine mounting bracket front.

(c) Remove the 2 bolts and front engine mounting insulator.





HINT
Only perform this procedure when replacement of the engine mounting insulator in necessary.

(d) Remove the 4 bolts and front crossmember.





71. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Removal

72. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH





(a) Remove the through bolt and nut.

(b) Remove the 4 bolts and engine mounting insulator LH.

73. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.





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

(b) Carefully remove the engine with transaxle from the vehicle.

74. REMOVE REAR ENGINE MOUNTING INSULATOR SUB-ASSEMBLY





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

75. REMOVE DRIVE SHAFT BEARING BRACKET





(a) Remove the 3 bolts and bracket.

76. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) Removal

77. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) Removal

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

79. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

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

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