Removal

2ZR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Fuel System: Precaution

2. REMOVE BATTERY

(a) Disconnect the cable from the battery terminal.

(b) Loosen the nut and remove the battery clamp.

(c) Remove the battery.

3. REMOVE BATTERY TRAY

4. REMOVE FRONT WHEELS

5. REMOVE ENGINE UNDER COVER LH

6. REMOVE ENGINE UNDER COVER RH

7. DRAIN ENGINE COOLANT Service and Repair

8. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

9. DRAIN AUTOMATIC TRANSAXLE OIL (for Automatic Transaxle)

10. REMOVE FRONT WIPER ARM HEAD CAP Removal

11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

13. REMOVE HOOD TO COWL TOP SEAL Removal

14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

15. REMOVE COWL TOP VENTILATOR LOUVER LH Removal

16. REMOVE FRONT WIPER MOTOR AND LINK Removal

17. REMOVE FRONT AIR SHUTTER SEAL RH

(a) Disengage the 2 claws and remove the front air shutter seal RH.

18. REMOVE OUTER COWL TOP PANEL

(a) Disengage the wire harness clamp.

(b) Remove the 9 bolts and remove the outer cowl top panel.

19. REMOVE AIR CLEANER ASSEMBLY

(a) Separate the intake air flow meter connector and 2 wire harness clamps.

(b) Separate the ventilation hose from the air cleaner hose.

(c) Unfasten the 2 clamps.

(d) Remove the air cleaner cap sub-assembly with air cleaner hose.

(e) Remove the air cleaner element.

(f) Separate the wire harness clamp from the air cleaner case.

(g) Remove the 2 bolts and remove the air cleaner case with air cleaner inlet.

20. REMOVE AIR CLEANER BRACKET

(a) Separate the wire harness clamp from the air cleaner bracket.

(b) Remove the 2 bolts and remove the air cleaner bracket.

21. REMOVE BATTERY CARRIER

(a) Separate the wire harness clamp from the battery carrier.

(b) Remove the 5 bolts and remove the battery carrier.

22. REMOVE NO. 2 CYLINDER HEAD COVER Removal

23. REMOVE FAN AND GENERATOR V BELT Removal

24. REMOVE NO. 2 RADIATOR HOSE

(a) Loosen the 2 clips and remove the No. 2 radiator hose.

25. REMOVE FRONT BUMPER COVER Removal

26. DISCONNECT NO. 1 RADIATOR HOSE Removal

27. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle) Removal

28. DISCONNECT NO. 2 OIL COOLER INLET HOSE (for Automatic Transaxle) Removal

29. REMOVE HOOD LOCK ASSEMBLY Removal

30. REMOVE NO. 1 COOLER COVER Removal

31. REMOVE UPPER RADIATOR SUPPORT ABSORBER Disassembly

32. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY Removal

33. REMOVE RADIATOR ASSEMBLY Removal

34. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY Removal

35. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

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

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

(a) Remove the 2 clips and the washers, and disconnect the 2 cables from the transaxle.

(b) Remove the 2 clips and disconnect the 2 cables from the control cable bracket.

37. SEPARATE UNION TO CHECK VALVE HOSE

(a) Loosen the clip and separate the union to check valve hose.

38. SEPARATE NO. 1 FUEL VAPOR FEED HOSE

(a) Separate the No. 1 fuel vapor feed hose from the vacuum switching valve assembly.

39. DISCONNECT ENGINE WIRE

(a) Remove the bolt and wire harness clamp and separate the transaxle earth wire (for Automatic Transaxle).

(b) Remove the bolt and 2 wire harness clamp and separate the transaxle earth wire (for Manual Transaxle).

(d) Pull up the lever and disconnect the connector from the engine control computer.

(e) Separate the 2 wire harness clamps.

(f) Remove the 2 connectors and clamp from the engine room junction block and disconnect the 2 wire harness clamps.

(g) Disconnect all wire harnesses and connectors.

NOTICE:
Make sure that no wire harness is connected between the body and engine.

40. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

(a) Disconnect heater water outlet hose A from the heater unit.

41. DISCONNECT HEATER WATER HOSE INLET A

(a) Disconnect heater water inlet hose A from the heater unit.

42. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

(b) 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 the O-rings that seal the pipe.
* Perform this work by hand. Do not use any tools.
* Do not forcibly bend, twist or turn 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 them to release them.

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

(a) Remove the 4 bolts, then separate the clutch release cylinder.

HINT
Suspend the clutch release cylinder with a piece of rope so as not to overload the clutch pipe.

44. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

45. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY Removal

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

47. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Removal

48. REMOVE CONSOLE PANEL UPPER Removal

49. REMOVE CONSOLE BOX COVER REAR Removal

50. REMOVE CONSOLE BOX CARPET Removal

51. REMOVE REAR CONSOLE BOX ASSEMBLY Removal

52. REMOVE FRONT CONSOLE BOX Removal

53. REMOVE FRONT FLOOR BRACE CENTER Removal

54. REMOVE FRONT EXHAUST PIPE ASSEMBLY

(a) Disconnect the heated oxygen sensor connector.

(b) Remove the grommet and pull the sensor connector out of the cabin through the floor panel.

(c) Remove the 2 bolts and 2 springs and separate the front exhaust pipe assembly from the exhaust tail pipe assembly.

(d) Remove the 2 bolts and 2 springs and separate the front exhaust pipe assembly from the exhaust manifold.

(e) Remove the 3 exhaust pipe supports and remove the front exhaust pipe assembly.

55. REMOVE FRONT AXLE SHAFT LH NUT Removal

56. REMOVE FRONT AXLE SHAFT RH NUT

HINT
The removal procedure for the RH side is the same as that for the LH side.

57. SEPARATE SPEED SENSOR FRONT LH Removal

58. SEPARATE SPEED SENSOR FRONT RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

59. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

60. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

61. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

62. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

63. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Removal

64. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

65. SEPARATE FRONT AXLE ASSEMBLY LH Removal

66. SEPARATE FRONT AXLE ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

67. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

68. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

69. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle) Removal

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

71. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

(b) Remove 2 bolts and remove the engine mounting stay RH.

NOTICE:
Be sure not to remove the other bolt A.

(d) Remove the through bolt and nut and separate the transverse engine mounting insulator.

(e) Remove the 6 bolts and remove the engine assembly with transaxle and front suspension crossmember from the vehicle.

72. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Remove the 5 bolts and remove the transverse engine mounting insulator.

73. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Remove the bolt and remove the air fuel ratio sensor bracket.

(b) Install the engine hangers with the bolts, as shown in the illustration.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

Part No.:

12281-37020 (engine hanger No. 1)

12282-37010 (engine hanger No. 2)

91552-81050 (bolt)

(c) Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember.

(d) Remove the through bolt from the engine moving control rod and remove the front suspension crossmember.

74. REMOVE ENGINE MOVING CONTROL ROD COVER Removal

75. REMOVE ENGINE MOVING CONTROL ROD (for Automatic Transaxle) Removal

76. REMOVE ENGINE MOVING CONTROL ROD (for Manual Transaxle) Removal

77. REMOVE FLYWHEEL HOUSING SIDE COVER Removal

78. REMOVE STARTER ASSEMBLY Removal

79. REMOVE NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) Removal

80. REMOVE NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) Removal

81. REMOVE NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle) Removal

82. REMOVE TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle)

83. SEPARATE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Removal

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

85. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transaxle)

(a) Remove the 2 bolts and the control cable bracket.

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

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

88. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

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

(a) Hold the crankshaft with SST.

SST : 09213-58013

91651-60855

SST : 09330-00021

(b) Remove the 8 bolts and remove the rear spacer, drive plate and front spacer.

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

(a) Hold the crankshaft with SST.

SST : 09213-58013

91651-60855

SST : 09330-00021

(b) Remove the 8 bolts and remove the flywheel sub-assembly.