Engine removal (RZ4E-TC)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

2. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

3. Coolant drain

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

Legend

  1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

4. Air duct removal

1) Remove the intake air duct from the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

2) Remove the PCV hose from the cylinder head cover and air duct.

Legend

  1. PCV hose
  2. Clamp

3) Remove the air duct from the air cleaner and turbocharger.

Legend

  1. Air duct

5. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the connector from the barometric pressure sensor.

3) Remove the air cleaner from the vehicle.

Legend

  1. Air cleaner
  2. MAF and IAT sensor
  3. Barometric pressure sensor

6. Intake hose removal

1) Remove the intake hose from the intercooler and turbocharger.

Legend

  1. Turbocharger
  2. Intercooler
  3. Intake hose
  4. Clamp

7. Air intake hose removal

1) Remove the air intake hose from the intake air duct and intercooler.

Legend

  1. Intercooler
  2. Air intake hose
  3. Intake air duct
  4. Clamp

8. Battery removal

1) Disconnect the battery ground cable from the frame.

2) Disconnect the battery cable from the battery.

3) Remove the battery bracket from the frame.

4) Remove the battery from vehicle.

Legend

  1. Battery cable
  2. Battery bracket
  3. Battery ground cable

9. Fuse box disconnect

1) Remove the fuse box cover from the fuse box.

2) Disconnect the engine harness from the fuse box.

3) Disconnect the battery harness from the fuse box.

10. Radiator upper hose removal

1) Remove the radiator upper hose from the water outlet pipe and radiator.

Legend

  1. Radiator upper hose

11. Radiator reserve tank removal

1) Disconnect the radiator reserve tank hose from the radiator.

2) Remove the radiator reserve tank from the fan guide.

12. Fan guide removal

1) Remove the fan shroud from the fan guide.

2) Remove the fan guide from the radiator.

Legend

  1. Fan shroud
  2. Fan guide
  3. Radiator

13. Cooling fan belt removal

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt removal".

14. Freezer compressor removal

1. Freezer specifications

1) Remove the freezer compressor from the freezer compressor bracket.

2) Remove the tension pulley from the freezer compressor bracket.

3) Remove the freezer compressor bracket from the cylinder block.

15. Power steering oil pump disconnect

1) Install the bolt and nut to the power steering oil pump shaft.

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft } M10 x 1.5 nut

Legend

  1. M10 x 1.5 bolt
  2. M10 x 1.5 nut
  3. Power steering oil pump pulley
  4. Power steering oil pump shaft

Caution

  • Do not tighten the bolt to the hole edge of the power steering oil pump shaft, but create a clearance.

Legend

  1. M10 x 1.5 bolt
  2. M10 x 1.5 nut
  3. Power steering oil pump shaft
  4. Power steering oil pump pulley

Legend

a. Gap

2) Remove the power steering oil pump pulley from the power steering oil pump.

Note

  • Secure the M10 x 1.5 nut with a tool, and loosen the pulley mounting bolt.

3) Disconnect the power steering oil pump from the generator bracket.

Note

  • Secure with wire at an appropriate position as a set with the hoses.

16. Generator removal

1) Disconnect the connector from the generator.

2) Disconnect the B-terminal from the generator.

3) Remove the generator from the generator bracket.

17. A/C compressor disconnect

1) Disconnect the pipe clip from the air duct bracket.

2) Disconnect the A/C compressor from the generator bracket.

Note

  • Secure with wire at an appropriate position as a set with the hoses.

18. Cooling fan removal

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.

19. Glove box removal

1) Remove the glove box from the instrument panel.

RHD

Legend

  1. Glove box

LHD

Legend

  1. Glove box

20. Instrument panel passenger-side lower cover removal

1) Remove the instrument panel passenger-side lower cover from the instrument panel.

RHD

Legend

  1. Instrument panel passenger-side lower cover
  2. Clip

LHD

Legend

  1. Instrument panel passenger-side lower cover
  2. Clip

2) Disconnect the connector from the instrument panel passenger-side lower cover.

21. ECM disconnect

1) Disconnect the connector from the ECM.

2) Pull out the harness to the engine room side.

3) Disconnect the harness from the frame.

22. Vacuum hose disconnect

1) Disconnect the vacuum hose from the vacuum pipe.

23. Catalytic converter removal

Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter removal".

24. Radiator lower hose disconnect

1) Disconnect the radiator lower hose from the water intake pipe.

Legend

  1. Radiator lower hose

25. Transmission removal

Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission removal".

26. Clutch removal

Refer to "5.Transmission, Transaxle 5E.Clutch System(MVL) Clutch removal".

27. Fuel hose disconnect

1) Disconnect the fuel feed hose from the fuel supply pump.

2) Disconnect the fuel return hose from the fuel leak-off pipe.

Legend

  1. Fuel feed hose
  2. Fuel return hose

28. Engine removal

1) Install the special tool to the generator bracket.


SST: 5-8840-3226-0 - front engine hanger

Legend

  1. 5-8840-3226-0

2) Install special tool to the flywheel housing.


SST: 5-8840-3170-0 - rear engine hanger

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Legend

  1. 5-8840-3170-0

3) Install the wire to the engine hanger and hoist.

4) Hold up the engine as high as not to be lifted up.

5) Disconnect the engine foot from the engine mounting.

Note

  • Loosen the engine mounting fixing bolts from above the engine using an extension bar that is 600 mm {23.6 in} or longer.

Legend

  1. Engine foot
  2. Engine mounting

6) Remove the engine from vehicle.

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