Removal

1NZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
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 AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Removal
9. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) Removal
10. REMOVE FRONT WIPER ARM HEAD CAP Removal
11. REMOVE FRONT WIPER ARM LH Removal
12. REMOVE FRONT WIPER ARM RH Removal
13. REMOVE HOOD TO COWL TOP SEAL (for Hatchback) Removal
14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback) Removal
15. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback) Removal
16. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) Removal
17. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) Removal
18. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan) Removal
19. REMOVE FRONT WIPER MOTOR AND LINK Removal

20. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback)
(a) Disengage the claw and remove cowl to register duct sub-assembly No. 2.

21. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan)
(a) Disengage the 3 claws and remove the front air shutter seal RH.
22. REMOVE COWL TOP PANEL OUTER (for Hatchback)

(a) Disengage the wire harness clamp.

(b) Remove the 9 bolts and remove the cowl top panel outer.
23. REMOVE COWL TOP PANEL OUTER (for Sedan)

(a) Disengage the wire harness clamp.

(b) Remove the 2 bolts and remove the cowl top to cowl inner brace.

(a) Separate the intake air flow meter connector and the wire harness clamp.
(b) Separate the fuel vapor feed hose and fuel vapor feed hose No. 1 from the vacuum switching valve assembly.
(c) Separate the vacuum switching valve connector and the wire harness clamp.
(d) Separate the ventilation hose from the air cleaner hose.
(e) Release the air cleaner cap sub-assembly with air cleaner hose No. 1.
(f) Loosen the air cleaner hose clamp on the throttle body side and remove the air cleaner cap and the air cleaner hose.
(g) Remove the air cleaner element.

(h) Separate the wire harness clamp from the air cleaner case.
(i) Remove the 2 bolts and remove the air cleaner case with air cleaner inlet No. 1.

25. 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.

26. REMOVE BATTERY CARRIER
(a) Separate the wire harness clamp from the battery carrier.
(b) Remove the 5 bolts and remove the battery carrier.

27. DISCONNECT RADIATOR HOSE NO. 3
(a) Disconnect radiator hose No. 3 from the water filler.

28. DISCONNECT RADIATOR RESERVOIR TANK HOSE
(a) Disconnect the radiator reservoir tank hose from the water filler.

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

30. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle)
(a) Loosen the clip and disconnect the oil cooler outlet hose.

31. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle)
(a) Loosen the clip and disconnect the oil cooler inlet hose.
32. REMOVE CYLINDER HEAD COVER NO. 2 Removal
33. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Removal
34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Removal
35. DISCONNECT UNION TO CHECK VALVE HOSE
(a) Disconnect the union to check valve hose from the booster vacuum tube.

36. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
(a) Disconnect heater water outlet hose A from the heater unit.

37. DISCONNECT HEATER WATER INLET HOSE A
(a) Disconnect heater water inlet hose A from the heater unit.
38. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove fuel pipe clamp No. 1.

(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 to release them.

39. REMOVE FAN AND GENERATOR V BELT Removal
40. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
(a) Disconnect the connector.
(b) Remove the 4 bolts and separate the with pulley compressor assembly.
HINT: Remove the compressor assembly together with the low and high pressure hoses, then suspend them from the body with a piece of rope.

41. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Removal
42. DISCONNECT ENGINE WIRE

(a) Pull up the lever and disconnect the connector of the engine control computer.

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

(c) Remove the bolt and separate the earth wire of the engine room wire harness.
(d) Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.
43. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal
44. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY Removal
45. REMOVE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1 Removal
46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)
47. REMOVE SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle) Removal
48. REMOVE CONSOLE BOX REAR COVER (for Hatchback) Removal
49. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (for Sedan) Removal
50. REMOVE INSTRUMENT PANEL FINISH PANEL END LH (for Sedan) Removal
51. REMOVE INSTRUMENT PAD LOWER LH (for Sedan) Removal
52. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for Sedan) Removal
53. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Sedan) Removal
54. REMOVE CONSOLE BOX CARPET (for Sedan) Removal
55. REMOVE REAR CONSOLE BOX ASSEMBLY Removal
56. REMOVE HEATED OXYGEN SENSOR Removal
57. REMOVE EXHAUST PIPE ASSEMBLY FRONT Removal
58. REMOVE FRONT AXLE SHAFT LH NUT Removal
59. REMOVE FRONT AXLE SHAFT RH NUT Removal
60. SEPARATE SPEED SENSOR FRONT LH (w/ ABS) Removal
61. SEPARATE SPEED SENSOR FRONT RH (w/ ABS) Removal
62. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal
63. SEPARATE TIE ROD END SUB-ASSEMBLY RH Removal
64. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal
65. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH Removal
66. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH Removal
67. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH Removal
68. SEPARATE FRONT AXLE ASSEMBLY LH Removal
69. SEPARATE FRONT AXLE ASSEMBLY RH Removal
70. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal
71. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal
72. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle)

73. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)
(a) Remove the 6 torque converter set bolts.
74. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

(b) Remove the 5 bolts and the nut and remove the engine mounting insulator RH.

(d) Remove the 6 bolts, and remove the engine assembly with transaxle and the front suspension crossmember from the vehicle.
75. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Remove the bolt and remove the radio setting condenser.
(b) Remove the bolt and remove the oxygen sensor wiring bracket.

(c) Install the engine hangers with the bolts, as shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
Part No.:
12281-21010 for engine hanger
91642-81025 for bolt
(d) Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember.
(e) Remove the through bolt from the engine moving control rod and remove the front suspension crossmember.
76. REMOVE VENTILATION HOSE
(a) Loosen the 2 clips and remove the ventilation hose.
77. REMOVE VENTILATION HOSE NO. 2
(a) Loosen the clips and remove ventilation hose No. 2.
78. REMOVE FUEL TUBE SUB-ASSEMBLY

(a) Disengage the claw and remove fuel pipe clamp No. 2.

(b) Pinch the fuel tube connector retainer from both sides, disconnect the fuel tube connector and separate the fuel tube from 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 to release them.

79. REMOVE WATER FILLER SUB-ASSEMBLY
(a) Disconnect radiator hose No. 1 from the cylinder head.
(b) Remove the 2 nuts and remove the water filler sub-assembly.
80. REMOVE HEATER WATER INLET HOSE A
(a) Disconnect heater water inlet hose A from the cylinder head.
81. REMOVE FLYWHEEL HOUSING SIDE COVER Removal
82. REMOVE STARTER ASSEMBLY Removal
83. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

(a) Remove the 7 bolts and remove the automatic transaxle with torque converter.

84. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)
(a) Hold the crankshaft with SST.
SST: 09960-10010
09962-01000
09963-01000
(b) Remove the 6 bolts, drive plate spacer FR, drive plate and ring gear sub-assembly and drive plate spacer RR.
85. REMOVE CONTROL CABLE BRACKET (for Manual Transaxle) Removal
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 FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
(a) Hold the crankshaft with SST.
SST: 09960-10010
09962-01000
09963-01000
(b) Remove the 6 bolts and flywheel.
90. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
91. REMOVE IGNITION COIL NO. 1
(a) Disconnect the connectors of the ignition coils.
(b) Remove the bolt and remove all the ignition coils.
92. REMOVE GENERATOR ASSEMBLY Removal
93. REMOVE INTAKE MANIFOLD

(a) Disconnect the union to connector tube hose from the booster vacuum tube.
(b) Disconnect the engine wire from the intake manifold.

(d) Disconnect the water by-pass hose from water bypass pipe No. 1.
(e) Disconnect the throttle with motor body assembly connector.

(f) Remove the 3 bolts and 2 nuts in the order shown in the illustration and remove the intake manifold.
(g) Remove the gasket from the intake manifold.

94. REMOVE WATER BY-PASS PIPE NO. 1
(a) Remove the 2 bolts and 2 nuts and remove water by-pass pipe No. 1.

95. REMOVE BOOSTER VACUUM TUBE
(a) Remove the 2 bolts and remove the booster vacuum tube.
96. REMOVE ENGINE WIRE
(a) Disconnect all the sensor connectors and wire harness clamps from the engine assembly and remove the engine wire harness.

97. REMOVE WIRE HARNESS CLAMP BRACKET
(a) Remove the 2 bolts and remove the 2 wire harness clamp brackets.
98. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
(a) Remove the 4 bolts and remove the exhaust manifold heat insulator.
99. REMOVE MANIFOLD SUPPORT BRACKET
(a) Remove the 3 bolts and remove the manifold support bracket.
100. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and 2 nuts and remove the exhaust manifold.

101. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY
(a) Remove the bolt and nut and remove the drive shaft heat insulator.