Diesel Data: Automotive Repair
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Removal








2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal
2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
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 AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)
HINT:
- Removal for U250E.
- Removal for U140F.

9. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)
HINT: for E351.

10. DRAIN TRANSFER OIL (for 4WD) Replacement
11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY





(a) Remove the 2 nuts and No. 1 engine cover sub-assembly.
12. SEPARATE RADIATOR RESERVE TANK ASSEMBLY





(a) Remove the 3 bolts and separate the radiator reserve tank assembly.
13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Removal
14. REMOVE AIR CLEANER CASE
(a) Remove the air cleaner filter element.





(b) Disconnect the clamp of the engine wire.
(c) Remove the 3 bolts and air cleaner case.
15. REMOVE BATTERY





(a) Remove the bolt, nut and battery clamp.
(b) Remove the battery and battery insulator.
16. REMOVE BATTERY CARRIER
(a) Remove the battery tray.





(b) Separate the 2 wire harness clamps from the battery carrier.
(c) Remove the 4 bolts and battery carrier.
17. SEPARATE WIRE HARNESS





(a) Disconnect the 3 connectors from the engine room relay block.
(b) Remove the 2 nuts and disconnect the wire harnesses from the engine room relay block.
(c) Using a screwdriver, unlock the 2 claws.
(d) Pull the engine room relay block upward.





(e) Pull up the lever and disconnect the ECM connector.
(f) Disconnect the clamp.





(g) Remove the bolt and disconnect the ground cable and clamp (for Manual Transaxle).





(h) Remove the bolt and disconnect the ground cable and clamp (for Automatic Transaxle).
18. REMOVE THROTTLE BODY ASSEMBLY Removal
19. REMOVE V-RIBBED BELT Removal
20. REMOVE GENERATOR ASSEMBLY Removal
21. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY
(a) Disconnect the connector.





(b) Remove the 2 bolts and 2 nuts.





(c) Using a "TORX" socket wrench (E8), remove the 2 stud bolts and compressor with pulley assembly.
HINT: Secure the compressor and hoses off to the side instead of discharging the A/C system.

22. DISCONNECT NO. 2 RADIATOR HOSE





(a) Disconnect the No. 2 radiator hose from the inlet water.
23. DISCONNECT NO. 1 RADIATOR HOSE





(a) Disconnect the No. 1 radiator hose from the cylinder head.
24. DISCONNECT OIL COOLER HOSE (for Automatic Transaxle)





(a) Disconnect the 2 oil cooler hoses.
25. DISCONNECT BREATHER HOSE (for Automatic Transaxle)





(a) Disconnect the breather hose.
26. DISCONNECT OUTLET HEATER WATER HOSE





(a) Disconnect the outlet heater water hose.
27. DISCONNECT INLET HEATER WATER HOSE





(a) Disconnect the inlet heater water hose.
28. REMOVE FUEL TUBE SUB-ASSEMBLY





(a) Release the claw and 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 or 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.

29. DISCONNECT UNION TO CONNECTOR TUBE HOSE





(a) Disconnect the union to connector tube hose.
30. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
HINT: for E351.

31. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
(a) U250E Automatic Transaxle:




(1) Remove the nut and disconnect the control cable assembly from the control shaft lever.
(2) Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.




(3) Disconnect the control cable assembly from the control cable bracket.
(b) U140F Automatic Transaxle:




(1) Remove the nut and disconnect the control cable assembly from the control shaft lever.
(2) Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.




(3) Disconnect the control cable assembly from the control cable bracket.
32. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)





(a) Remove the 2 clips and disconnect the 2 transmission control cables from the control cable bracket*1.
(b) Remove the 2 clips and disconnect the 2 transmission control cables from the transaxle*2.
33. SECURE STEERING WHEEL Removal
34. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal
35. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
HINT:
- Removal for 2WD.
- Removal for 4WD.

36. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal
37. REMOVE CENTER EXHAUST PIPE ASSEMBLY Removal
38. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal
39. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) Removal
40. REMOVE FRONT AXLE SHAFT LH NUT Removal
41. REMOVE FRONT AXLE SHAFT RH NUT
HINT: Perform the same procedure for the LH side.

42. SEPARATE FRONT SPEED SENSOR LH Removal
43. SEPARATE FRONT SPEED SENSOR RH
HINT: Perform the same procedure for the LH side.

44. SEPARATE TIE ROD END SUB-ASSEMBLY LH
HINT:
- Removal for 2WD.
- Removal for 4WD.

45. SEPARATE TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

46. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal
47. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

48. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Removal
49. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

50. SEPARATE STEERING KNUCKLE WITH AXLE HUB LH





(a) Put matchmarks on the drive shaft and axle hub.
NOTE: Do not punch the marks.

(b) Using a plastic-faced hammer, disconnect the front axle assembly LH.
NOTICE:
- Be careful not to damage the boot or speed sensor rotor.
- Do not excessively push out the drive shaft from the axle assembly.

51. SEPARATE STEERING KNUCKLE WITH AXLE HUB RH
HINT: Perform the same procedure for the LH side.

52. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal
53. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH Removal
54. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Removal
55. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) Removal
56. SEPARATE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)
HINT:
- Removal for U250E.
- Removal for U140F.

57. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
HINT:
- Removal for 2WD.
- Removal for 4WD.

58. REMOVE CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY
HINT:
- Removal for 2WD.
- Removal for 4WD.

59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE





(a) Set the engine assembly with transaxle on the engine lifter.
NOTE: Place the engine on wooden blocks or equivalent so that the engine is level.





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





(c) Remove the through bolt and nut, and separate the engine mounting insulator LH.
(d) Carefully remove the engine with transaxle from the vehicle.
60. INSTALL ENGINE HANGERS





(a) Install the No. 1 and No. 2 engine hangers with new bolts as shown in the illustration.
Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)










(b) Using an engine sling device and a chain block, suspend the engine assembly with transaxle.
61. REMOVE FRONT ENGINE MOUNTING INSULATOR





(a) Remove the through bolt and nut, and separate the front engine mounting insulator.
62. REMOVE REAR ENGINE MOUNTING INSULATOR (for 2WD)





(a) Remove the through bolt and separate the rear engine mounting insulator.
63. REMOVE REAR ENGINE MOUNTING INSULATOR (for 4WD)





(a) Remove the through bolt and separate the rear engine mounting insulator.
64. REMOVE ENGINE MOUNTING INSULATOR LH





(a) Remove the 4 bolts and engine mounting insulator LH.
65. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH





(a) Remove the 3 bolts and engine mounting insulator sub-assembly RH.
66. REMOVE DRIVE SHAFT BEARING BRACKET (for 2WD)





(a) Remove the 3 bolts and bracket.
67. REMOVE STARTER ASSEMBLY (for Automatic Transaxle) Removal
68. REMOVE STARTER ASSEMBLY (for Manual Transaxle) Removal
69. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
HINT: for E351.

70. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
HINT:
- Removal for U250E.
- Removal for U140F.

71. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)
HINT: for E351.

72. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)
HINT: for E351.

73. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Removal
74. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Removal
75. REMOVE ENGINE WIRE
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