Removal

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
HINT: Technician Safety Information.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE FRONT FENDER APRON SEAL RH
8. DRAIN ENGINE OIL Replacement
9. DRAIN ENGINE COOLANT Testing and Inspection
10. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Removal
11. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) Removal
12. DRAIN BRAKE FLUID (for Manual Transaxle) Removal
13. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
HINT: Removal.

14. REMOVE COWL TOP PANEL OUTER SUB-ASSEMBLY Removal
15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Remove the 2 nuts and cover.
16. REMOVE V-RIBBED BELT Removal
17. REMOVE AIR CLEANER INLET ASSEMBLY

(a) Remove the 2 bolts, clamp and air cleaner inlet.
18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal
19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Disconnect the hose clamp.
(b) Remove the 3 bolts and air cleaner case.
20. REMOVE BATTERY

(a) Loosen the nut, and remove the bolt and battery clamp.
(b) Remove the battery and battery tray.
21. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the 2 bolts and No. 2 mounting stay RH.
22. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) Remove the bolt and disconnect the ground cable.

(b) Remove the 3 bolts and the engine moving control rod with bracket.
23. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH

(a) Remove the 3 bolts and No. 2 mounting bracket RH.
24. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR

(a) Remove the clamp and disconnect the vacuum hose connector.
25. DISCONNECT RADIATOR HOSE INLET

(a) Remove the clamp and disconnect the radiator hose inlet.
26. DISCONNECT RADIATOR HOSE OUTLET

(a) Remove the clamp and disconnect the radiator hose outlet.
27. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) Removal
28. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) Removal
29. DISCONNECT HEATER WATER HOSE INLET

(a) Disconnect the heater inlet water hose.
30. DISCONNECT HEATER WATER HOSE OUTLET

(a) Disconnect the heater outlet water hose.
31. REMOVE ECM
HINT: Removal.

32. DISCONNECT ENGINE WIRE

(a) Disconnect the engine wire from the engine room relay block.
(1) Remove the nut and separate the wire harness.
(2) Using a screwdriver, unlock the engine room relay block. Pull the engine room relay block upward.
(3) Disconnect the engine wire connectors.

(b) Remove the clamp from the bracket.

(c) Remove the 2 bolts and clamp from the body.
33. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Remove the clip and nut, and separate the control lever.
(b) Separate the cable from the transaxle.
34. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Remove the 2 clips and 2 washers and disconnect the 2 cables from the transaxle.
(b) Remove the 2 clips and disconnect the 2 cables from the control cable bracket.
35. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Disconnect the No. 1 oil reservoir to pump hose.
36. DISCONNECT RETURN TUBE SUB-ASSEMBLY

(a) Disconnect the return tube sub-assembly.
37. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle)
HINT: Removal.

38. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
HINT: Disassembly.

39. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

(b) Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration.
NOTICE:
- Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
- Disconnect the connector by hand.
- Do not bend, fold or rotate the nylon tube.
- If the pipe and connector are stuck together, push and pull the connector until it becomes free.
- Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

40. REMOVE GENERATOR ASSEMBLY Removal
41. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH

(a) Disconnect the connector.
(b) Remove the 4 bolts and separate the compressor.
HINT: Secure the compressor and hoses off to the side instead of discharging the A/C system.

42. REMOVE FRONT EXHAUST PIPE ASSEMBLY
HINT: Removal.

43. REMOVE FRONT AXLE HUB NUT LH Removal
44. REMOVE FRONT AXLE HUB NUT RH
HINT: Use the same procedure described for the LH side.

45. REMOVE FRONT STABILIZER LINK ASSEMBLY LH Removal
46. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

47. REMOVE FRONT SPEED SENSOR LH Removal
48. REMOVE FRONT SPEED SENSOR RH
HINT: Use the same procedure described for the LH side.

49. DISCONNECT TIE ROD ASSEMBLY LH Removal
50. DISCONNECT TIE ROD ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

51. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH Removal
52. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedure described for the LH side.

53. SEPARATE FRONT AXLE ASSEMBLY LH Removal
54. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

55. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) Removal
56. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Remove the 2 bolts and exhaust pipe support bracket.
57. SEPARATE STEERING SLIDING YOKE Removal
58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.
(b) Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.

(c) Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.
(d) Carefully remove the engine assembly from the vehicle using the engine lifter.

(e) Install the 2 engine hangers as shown in the illustration.
Parts No.:

Torque: 38 Nm (387 kgf-cm, 28ft-lbf)
(f) Using a chain block and an engine sling device, hang the engine assembly.
59. REMOVE VANE PUMP ASSEMBLY
(a) Disconnect the oil pressure switch connector.

(b) Loosen the 2 bolts and remove the vane pump from the engine.
60. REMOVE FRONT FRAME ASSEMBLY

(a) A/T:
Remove the nut from the engine mounting insulator LH.

(b) M/T:
Remove the bolt from the engine mounting insulator LH.

(d) Remove the bolt from the engine mounting insulator FR.

(e) M/T:
Remove the bolt from the engine lateral control rod.
(f) Raise the engine assembly and separate the front frame.
61. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal
62. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal
63. REMOVE ENGINE WIRE
64. REMOVE STARTER ASSEMBLY (for Manual Transaxle) Removal
65. REMOVE STARTER ASSEMBLY (for Automatic Transaxle) Removal
66. SEPARATE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
HINT: Removal.

67. SEPARATE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
HINT: Removal.

68. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Removal
69. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) Disassembly
70. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) Disassembly
71. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Removal
72. INSTALL ENGINE STAND
(a) Install the engine onto a engine stand with the bolts.
73. REMOVE FUEL DELIVERY PIPE WITH INJECTOR Removal
74. REMOVE INTAKE MANIFOLD

(a) Remove the 5 bolts, 2 nuts, and intake manifold.

(b) Remove the gasket from the intake manifold.
75. REMOVE INTAKE AIR CONTROL VALVE (for PZEV) Removal
76. REMOVE NO. 2 VENTILATION HOSE
77. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

(a) Remove the intake manifold insulator from the cylinder block.
78. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.
79. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
80. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the bolt and oil level gauge guide.
(b) Remove the O-ring from the oil level gauge guide.
81. REMOVE MANIFOLD STAY

(a) Remove the bolt, nut and stay.
82. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and stay.
83. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) For PZEV:

(1) Disconnect the air-fuel ratio sensor connector.

(2) Remove the 5 nuts, manifold converter and gasket.
(b) Except for PZEV:

(1) Remove the 4 bolts and No. 1 insulator.

(2) Disconnect the air-fuel ratio sensor connector.

(3) Remove the 5 nuts, manifold converter and gasket.
84. REMOVE WATER INLET Removal
85. REMOVE THERMOSTAT Removal
86. REMOVE NO. 1 WATER BY-PASS PIPE

(a) Remove the bolt, 2 nuts and No. 1 water by-pass pipe with the gasket.
87. REMOVE OIL COOLER PIPE (w/ Oil Cooler)

(a) Remove the bolt, 2 nuts and oil cooler pipe with the gasket.
88. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 3 bolts and engine mounting bracket RH.
89. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 4 bolts and 4 ignition coils.
90. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
91. REMOVE KNOCK SENSOR
(a) Disconnect the sensor connector.
(b) Remove the nut and sensor.
92. REMOVE RADIO SETTING CONDENSER

(a) Remove the bolt and radio setting condenser.
93. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
94. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

(a) Using SST, remove the sensor and gasket.
SST: 09817-33190