Removal

1ZZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
(a) Discharge fuel system pressure (Technician Safety Information).
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE CYLINDER HEAD COVER NO. 2
(a) Remove the cylinder head cover No. 2 (Removal).
7. DRAIN ENGINE COOLANT
(a) Drain the engine coolant (Testing and Inspection).
8. DISCONNECT RADIATOR HOSE INLET
9. DISCONNECT RADIATOR HOSE OUTLET
10. DISCONNECT OIL COOLER INLET HOSE NO. 1 (for Automatic Transaxle)
11. DISCONNECT OIL COOLER OUTLET HOSE NO. 1 (for Automatic Transaxle)
12. REMOVE RADIATOR ASSEMBLY (w/ Air Conditioning System)
(a) Remove the radiator assembly (Removal).
13. REMOVE BATTERY
14. REMOVE BATTERY TRAY
15. REMOVE BATTERY CARRIER

(a) Remove the 4 bolts, then remove the battery carrier.
16. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Remove the air cleaner cap sub-assembly (Removal).
17. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Disconnect the clamp [A] of the engine wire.
(b) Remove the 3 bolts [B] from the air cleaner case.
(c) Disconnect the air cleaner case from the air cleaner inlet No. 1 [C].
18. DISCONNECT FUEL TUBE SUB-ASSEMBLY
(a) Disconnect the fuel tube sub-assembly (Removal).
SST: 09268-21010
19. DISCONNECT UNION TO CHECK VALVE HOSE
20. DISCONNECT HEATER INLET WATER HOSE

(a) Disconnect the heater inlet water hose from the air conditioner tube.
21. DISCONNECT HEATER OUTLET WATER HOSE

(a) Disconnect the heater outlet water hose from the air conditioner tube.
22. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
(a) Separate the transmission control cable assembly (Removal).
23. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
(a) Separate the transmission control cable assembly (Removal).
24. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
(a) Separate clutch release cylinder assembly (Removal).
25. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt (Removal).
26. REMOVE GENERATOR ASSEMBLY
(a) Remove the generator assembly (Removal).
27. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
(a) Separate the compressor and magnetic clutch (Removal).

HINT: Secure the compressor and hoses off to the side instead of discharging the air conditioning system.

28. SEPARATE RETURN TUBE SUB-ASSEMBLY

(a) Separate the vane pump oil reservoir from the oil reservoir bracket.
(b) Remove the 2 bolts, then separate the return tube.
29. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
(a) Remove the glove compartment door assembly (Removal).
30. REMOVE FRONT DOOR SCUFF PLATE RH
(a) Remove the front door scuff plate RH (Removal).
31. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH (Removal).
32. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junction block.
(b) Pull out the engine wire.
(c) Remove the engine room relay block cover.

(d) Disconnect the 3 connectors [D].
(e) Disconnect the engine wire harness by pulling it upward [E].

(f) Remove the engine wire clamp.

(g) Remove the bolt, then disconnect the ground terminal.
33. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the floor panel brace front (Removal).
34. REMOVE EXHAUST PIPE ASSEMBLY FRONT
(a) Remove the exhaust pipe assembly front (Removal).
35. REMOVE COLUMN HOLE COVER SILENCER SHEET
36. SEPARATE STEERING INTERMEDIATE SHAFT
(a) Separate the steering intermediate shaft (Removal).
37. REMOVE FRONT AXLE SHAFT LH NUT
(a) Remove the front axle shaft LH nut (Removal).
SST: 09930-00010
38. REMOVE FRONT AXLE SHAFT RH NUT
SST: 09930-00010

HINT: Perform the same procedure as above on the opposite side.

39. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
(a) Separate the front stabilizer link assembly LH (Removal).
40. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

41. SEPARATE SPEED SENSOR FRONT LH (w/ ABS)
(a) Separate the speed sensor front (Removal).
42. SEPARATE SPEED SENSOR FRONT RH (w/ ABS)

HINT: Perform the same procedure as above on the opposite side.

43. SEPARATE TIE ROD END SUB-ASSEMBLY LH
(a) Separate the tie rod end sub-assembly LH (Removal).
SST: 09628-62011
44. SEPARATE TIE ROD END SUB-ASSEMBLY RH
SST: 09628-62011

HINT: Perform the same procedure as above on the opposite side.

45. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
(a) Separate the front suspension arm sub-assembly lower No. 1 LH (Removal).
46. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Perform the same procedure as above on the opposite side.

47. SEPARATE FRONT AXLE ASSEMBLY LH
(a) Separate the front axle assembly LH (Removal).
48. SEPARATE FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

49. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.

(b) Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH.

(d) Remove the 6 bolts as shown in the illustration.
(e) Carefully remove the engine with transaxle from the engine compartment.

(f) Install the engine hanger (12281-22021) with the bolt (91512-B1016 or 90080-10161).
Torque: 38 Nm (387 kg-cm, 28 ft-lb)
(g) Install the engine hanger (12281-15050) with the bolt (91512-B1016 or 90080-10161).
Torque: 38 Nm (387 kg-cm, 28 ft-lb)

HINT: Securely install the front engine hanger (12281-22021) and the rear engine hanger (12281-15050) onto the engine assembly.

(h) Attach the engine sling and hang the engine with the chain block.
50. SEPARATE VANE PUMP ASSEMBLY
(a) Separate the vane pump assembly (Removal).
51. REMOVE FRONT SUSPENSION CROSSMEMBER WITH CENTER MEMBER

(a) Remove the through bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR.

(b) Remove the through bolt, then separate the engine mounting insulator RR from the engine mounting bracket RR.
(c) Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
52. REMOVE STARTER ASSEMBLY
(a) Remove the starter assembly (Removal).
53. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
(a) Remove the manual transaxle assembly (Removal).
54. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
(a) Remove the automatic transaxle assembly (Removal).
55. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)
(a) Remove the clutch cover assembly (Removal).
56. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)
(a) Remove the clutch disc assembly (Removal).
57. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
(a) Remove the flywheel sub-assembly (Removal).
SST: 09960-10010
09962-01000
09963-01000
58. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)
(a) Remove the drive plate & ring gear sub-assembly (Removal).
SST: 09960-10010
09962-01000
09963-01000
59. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the ignition coil assembly (Removal).
60. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(a) Remove the fuel delivery pipe sub-assembly (Removal).
61. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
62. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold (Removal).
63. REMOVE OIL LEVEL GAUGE GUIDE

(a) Disconnect the crankshaft position sensor clamp.
(b) Remove the bolt, then remove the oil level gauge guide.
64. REMOVE WATER BY-PASS PIPE NO. 1

(a) Disconnect the knock sensor clamp.
(b) Remove the 2 bolts and 2 nuts, then remove the water by-pass pipe No. 1.
(c) Remove the gasket from the cylinder block.
65. REMOVE WATER INLET
(a) Remove the water inlet (Removal).
66. REMOVE THERMOSTAT
67. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Remove the engine oil pressure switch assembly (Testing and Inspection).
68. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt, then remove the camshaft position sensor.
69. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the 2 bolts, then remove the crankshaft position sensor.
70. REMOVE KNOCK SENSOR

(a) Remove the nut, then remove the knock sensor.
71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the V-ribbed belt tensioner assembly (Removal).
72. REMOVE MANIFOLD STAY

(a) Remove the 3 bolts and manifold stay.
73. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Disconnect the air fuel ratio sensor connector [A].
(b) Remove the 4 bolts [B], then remove the exhaust manifold heat insulator.
74. REMOVE EXHAUST MANIFOLD

(a) Remove the 5 nuts, then remove the exhaust manifold.
(b) Remove the gasket from the cylinder head.
75. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

(a) Using SST, remove the engine coolant temperature sensor.
SST: 09817-33190
76. REMOVE RADIO SETTING CONDENSER

(a) Remove the bolt, then remove the condenser.
77. REMOVE WATER BY-PASS HOSE NO. 2
78. REMOVE RADIATOR HOSE INLET
79. REMOVE HEATER INLET WATER HOSE
80. REPLACE PARTIAL ENGINE ASSEMBLY