Removal

2ZR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions

2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

3. REMOVE FRONT WHEEL

4. REMOVE ENGINE UNDER COVER LH

5. REMOVE ENGINE UNDER COVER RH

6. DRAIN ENGINE COOLANT Service and Repair

7. DRAIN ENGINE OIL Replacement

8. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

HINT
Service and Repair for C59.

9. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

HINT
Removal for U341E.

10. REMOVE NO. 2 CYLINDER HEAD COVER

(a) Hold the rear of the cover and raise it to disengage the 2 clips on the rear of the cover. Continue to raise the cover to disengage the 2 clips on the front of the cover to remove the cover.

NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the cover to break.

11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal

12. REMOVE AIR CLEANER CASE

(a) Separate the air cleaner filter element from the air cleaner.

(b) Disconnect the engine wire harness clamp from air cleaner case.

(c) Remove the 3 bolts and the air cleaner case.

13. REMOVE BATTERY

(a) Disconnect the battery cables.

(b) Remove the bolt and loosen the nut.

(c) Remove the battery.

14. REMOVE BATTERY CARRIER

(a) Separate the 2 wire harness clamps from the battery carrier.

(b) Remove the 2 bolts.

(c) Separate the radiator pipe from the battery carrier.

(d) Remove the 4 bolts and battery carrier.

15. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disengage the clamp*1.

(b) Disconnect the No. 1 radiator hose from the cylinder head with the clamp*2.

16. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disconnect the No. 2 radiator hose from the water inlet hose.

17. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Remove the 2 clips and disconnect the 2 cables from the transaxle.

(b) Remove the 2 clips and disconnect the 2 cables from the control cable bracket.

18. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Disconnect the control cable from the control cable support.

(b) Remove the nut and disconnect the control cable from the control shaft lever.

(c) Remove the clip and disconnect the control cable from the control cable bracket.

(d) Remove the bolt and disconnect the clamp of the control cable.

19. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY

(a) Disconnect the fuel vapor feed hose.

20. DISCONNECT UNION TO CONNECTOR TUBE HOSE

(a) Disconnect the union to connector tube hose.

21. DISCONNECT OIL COOLER HOSE (for Automatic Transaxle)

(a) Disconnect the 2 oil cooler hoses from the oil cooler tube.

22. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose from the engine.

23. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose from the engine.

24. DISCONNECT 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 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, 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.
25. REMOVE V-RIBBED BELT Removal

26. REMOVE GENERATOR ASSEMBLY Removal

27. REMOVE FAN BELT ADJUSTING BAR

(a) Remove the bolt and fan belt adjusting bar.

28. SEPARATE COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)

(a) Disconnect the connector.

(b) Remove the 2 bolts and 2 nuts.

HINT
Secure the compressor and hoses off to the side instead of discharging the A/C system.

29. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)

(a) Remove the 4 bolts and clutch tube bracket, and separate the clutch release cylinder assembly.

30. DISCONNECT WIRE HARNESS

(a) Pull up the lever to disconnect the ECM connector and release the clamp.

(b) Remove the 2 nuts.

(c) Remove the 3 connectors and 2 clamps from the engine room junction block and disconnect the wire harness.

(d) Remove the bolt and clamp (for Manual Transaxle).

(e) Remove the bolt and clamp (for Automatic Transaxle).

(f) Disconnect all the wire harnesses and connectors.

Make sure that no wire harness is connected between the body and engine.

31. SECURE STEERING WHEEL Removal

32. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

33. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

34. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal

35. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

36. REMOVE FRONT AXLE SHAFT LH NUT Removal

37. REMOVE FRONT AXLE SHAFT RH NUT

HINT
Perform the same procedure for the LH side.

38. DISCONNECT FRONT SPEED SENSOR LH Removal

39. DISCONNECT FRONT SPEED SENSOR RH

HINT
Perform the same procedure for the LH side.

40. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

41. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

42. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

43. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

44. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Removal

45. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

46. SEPARATE STEERING KNUCKLE WITH AXLE HUB LH

(a) Put matchmarks on the drive shaft and axle hub.

NOTICE:
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 and speed sensor rotor.
* Do not excessively push out the drive shaft from the axle assembly.
47. SEPARATE STEERING KNUCKLE WITH AXLE HUB RH

HINT
Perform the same procedure for the LH side.

48. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

49. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

50. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH Removal

51. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH Removal

52. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle) Removal

53. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) Removal

54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Removal

55. REMOVE CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY Removal

56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

NOTICE:
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.

(d) Carefully remove the engine with transaxle from the vehicle.

57. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the bolt, nut and front engine mounting insulator.

58. REMOVE REAR ENGINE MOUNTING INSULATOR

(a) Remove the through bolt and rear engine mounting insulator.

59. REMOVE ENGINE MOUNTING INSULATOR LH

(a) Remove the 4 bolts and engine mounting insulator LH.

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

60. REMOVE ENGINE MOUNTING INSULATOR RH

(a) Disconnect the clamp, and release the relay block assembly.

(b) Remove the 3 bolts and radiator reserve tank.

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

61. INSTALL ENGINE HANGER

(a) Remove the bolt and wire harness bracket.

(b) Install the 2 engine hangers with the 2 bolts.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

62. REMOVE FLYWHEEL HOUSING SIDE COVER

63. REMOVE STARTER ASSEMBLY Removal

64. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

HINT
Removal for C59.

65. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

HINT
Removal for U341E.

66. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) Removal

67. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) Removal

68. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Removal

69. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Removal

70. REMOVE ENGINE WIRE