2NZ-FE ENGINE MECHANICAL  ENGINE ASSEMBLY  REMOVAL  


CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.


PROCEDURE

Hide 1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


Hide 2. DISCHARGE FUEL SYSTEM PRESSURE

Click hereEngine / Hybrid System>2NZ-FE FUEL>FUEL SYSTEM>PRECAUTION

Hide 3.ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL

Hide 4. SECURE STEERING WHEEL

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL

Hide 5.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION


Hide 6.REMOVE FRONT WHEELS

Click hereSuspension>TIRE / WHEEL>TIRE AND WHEEL>REMOVAL

Hide 51442C 7.REMOVE ENGINE UNDER COVER LH

a.

Remove the 2 bolts, 4 screws, 3 clips and engine under cover LH.


Hide 51441C 8.REMOVE ENGINE UNDER COVER RH

a.

Remove the 3 bolts, 4 screws, 3 clips and engine under cover RH.


Hide 11.DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

Click hereDrivetrain>C50 MANUAL TRANSMISSION / TRANSAXLE>MANUAL TRANSAXLE OIL>REPLACEMENT

Hide 12.DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>VALVE BODY ASSEMBLY>REMOVAL

Hide 11212 13.REMOVE NO. 2 CYLINDER HEAD COVER

a.
A143278

Remove the 4 nuts and No. 2 cylinder head cover.


Hide 23826 14.DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

a.
A182619C01
0,0 0,0 false

Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).


b.

Disconnect the connector.


Hide 17705 15.REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>THROTTLE BODY>REMOVAL

Hide 17701 16.REMOVE AIR CLEANER CASE SUB-ASSEMBLY

a.

Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.


b.
A154279

Disconnect the wire harness clamp from the air cleaner case sub-assembly.


c.

Remove the 3 bolts and air cleaner case sub-assembly.


Hide 17.REMOVE BATTERY

A311982

a.

Loosen the nut, and disconnect the cable from the positive (+) battery terminal.


b.

Remove the bolt, nut and battery clamp sub-assembly.


c.

Remove the battery and battery tray from the battery carrier.


d.
A312310C01
1.813,0.917 2.708,0.656 2.708,0.656 2.854,0.656 true 1.521,1.469 1.521,1.344 1.521,1.344 1.75,1.219 true 2.927,0.573 3.24,0.771 0.313,0.198 10 false *1 1.438,1.49 1.75,1.688 0.313,0.198 10 false *2
*1 Battery Clamp Bolt
*2 Battery Carrier Support


Remove the battery clamp bolt from the battery carrier support.


Hide 74411 18.REMOVE BATTERY CARRIER

a.
A308127

Disconnect the 2 wire harness clamps from the battery carrier.


b.
A154250

Remove the 2 bolts and disconnect the radiator pipe from the battery carrier.


c.
A308253

Remove the 4 bolts and battery carrier.


Hide 16571C 19.DISCONNECT NO. 1 RADIATOR HOSE

a.
A154266

Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.


Hide 16572D 20.DISCONNECT NO. 2 RADIATOR HOSE

a.
A154267

Slide the clip and disconnect the No. 2 radiator hose from the water inlet.


Hide 33820B 21.DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

a.
C304026N01
0.698,0.729 0.917,0.958 0.219,0.229 10 false A 1.51,1.583 1.729,1.813 0.219,0.229 10 false A 2.219,1.396 2.438,1.625 0.219,0.229 10 false B 2.125,0.698 2.344,0.927 0.219,0.229 10 false B

Remove the 2 clips (A) and disconnect the transmission control cable assembly from the manual transaxle assembly.


b.

Remove the 2 clips (B) and disconnect the transmission control cable assembly from the control cable bracket assembly.


Hide 33820B 22.DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>PARK / NEUTRAL POSITION SWITCH>REMOVAL

Hide 31470 23.SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)

a.
A154281

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


Hide 32921 24.REMOVE INLET NO. 1 OIL COOLER TUBE (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

Hide 32922 25.REMOVE OUTLET NO. 1 OIL COOLER TUBE (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

Hide 44774 26.DISCONNECT UNION TO CONNECTOR TUBE HOSE

a.
A154280

Slide the clip and disconnect the union to connector tube hose from the air tube.


Hide 87246 27.DISCONNECT OUTLET HEATER WATER HOSE

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>CYLINDER HEAD GASKET>REMOVAL

Hide 87245 28.DISCONNECT INLET HEATER WATER HOSE

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>CYLINDER HEAD GASKET>REMOVAL

Hide 23901 29.DISCONNECT FUEL TUBE SUB-ASSEMBLY

a.
A156317

Disengage the claw and remove the No. 1 fuel pipe clamp.


b.
A107343

Pinch the retainer as shown in the illustration, then pull the fuel tube connector off the fuel 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 to get on the parts when disconnecting them, as the fuel tube connector has O-rings that seal the fuel pipe.

·

Perform this work by hand. Do not use any tools.

·

Do not forcibly bend, kink or twist the nylon tube.

·

Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube sub-assembly.

·

If the fuel tube connector and fuel pipe are stuck, push and pull to release them.




Hide 27020 31.REMOVE GENERATOR ASSEMBLY

Click herePower Source / Network>2NZ-FE BATTERY / CHARGING>GENERATOR>REMOVAL

Hide 88310 32.SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY

a.
E261280

Disconnect the connector.


b.
E261281C03
1.833,0.729 1.802,0.698 false
V100135

Bolt
V100136

Nut


Remove the 2 bolts and 2 nuts.


c.
E261282

Using an E8 "TORX" socket wrench, remove the 2 stud bolts.


d.

Separate the compressor assembly with pulley from the engine assembly.

HINT:

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



Hide 33.DISCONNECT WIRE HARNESS

a.
A327684

Disengage the wire harness clamp.


b.

Pull up the lever and disconnect the ECM connector.


c.

Remove the No. 1 engine room relay block cover from the engine room relay block and junction block assembly.


d.
A285512

Remove the 2 nuts from the engine room relay block and junction block assembly.


e.

Disconnect the 3 wire harness connectors.


f.

Disengage the 2 claws to disconnect the wire harness from the engine room relay block and junction block assembly.


g.

for Manual Transaxle:

i.
A178171

Disengage the clamp to disconnect the engine wire from the engine mounting bracket LH.


ii.

Remove the bolt and disconnect the No. 3 engine wire from the manual transaxle assembly.



h.

for Automatic Transaxle:

i.
A327687

Disengage the clamp to disconnect the engine wire from the engine mounting bracket LH.


ii.

Remove the bolt and disconnect the No. 3 engine wire from the automatic transaxle assembly.



i.

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


Hide 45259A 34.REMOVE COLUMN HOLE COVER SILENCER SHEET

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL

Hide 45260 35.SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL

Hide 45025D 36.SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL

Hide 11361J 39.REMOVE FLYWHEEL HOUSING UNDER COVER

a.
C118502

Remove the flywheel housing under cover from the oil pan sub-assembly.


Hide 32101G 40.REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

Hide 51201 41.REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>REMOVAL

Hide 42.REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

a.

Set an engine lifter.

NOTICE:
·

Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

·

Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.




b.

Remove the center engine mounting member sub-assembly.

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>REMOVAL


c.
A192413

Remove the 2 bolts and nut, and separate the engine mounting insulator sub-assembly RH.


d.
A327506C01
0.052,0.052 0.427,0.292 0.375,0.24 12 false *A 0.083,2.135 0.458,2.375 0.375,0.24 12 false *B
*A for Manual Transaxle
*B for Automatic Transaxle


Remove the through bolt, nut and separate the engine mounting insulator LH.

HINT:

Because the nut has its own stopper, do not turn the nut. Loosen the through bolt with the nut secured.



e.

Carefully remove the engine assembly with transaxle from the vehicle.

NOTICE:

Make sure that the engine assembly with transaxle is clear of all wiring and hoses.



Hide 12361A 43.REMOVE FRONT ENGINE MOUNTING INSULATOR

HINT:

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


a.
A327507C01
0.042,0.052 0.417,0.292 0.375,0.24 12 false *A 0.073,2.208 0.448,2.448 0.375,0.24 12 false *B
*A for Manual Transaxle
*B for Automatic Transaxle


Remove the through bolt, nut and front engine mounting insulator from the front engine mounting bracket.

HINT:

Because the nut has its own stopper, do not turn the nut. Loosen the through bolt with the nut secured.



Hide 12371A 44.REMOVE REAR ENGINE MOUNTING INSULATOR

HINT:

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


a.
A327508C01
0.083,0.052 0.458,0.292 0.375,0.24 12 true *A 0.104,2.167 0.479,2.406 0.375,0.24 12 true *B
*A for Manual Transaxle
*B for Automatic Transaxle


Remove the through bolt and rear engine mounting insulator from the rear engine mounting bracket.


Hide 12372A 45.REMOVE ENGINE MOUNTING INSULATOR LH

HINT:

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


a.
A327509C01
0.052,0.063 0.427,0.302 0.375,0.24 12 true *A 0.083,2.427 0.458,2.667 0.375,0.24 12 true *B
*A for Manual Transaxle
*B for Automatic Transaxle


Remove the 4 bolts and engine mounting insulator LH.


Hide 12305 46.REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.


a.
C292590

Disengage the clamp to separate the reserve hose.


b.

Remove the reserve tank cap sub-assembly.


c.
C292591

Remove the 3 bolts and radiator reserve tank assembly.


d.
A180299

Remove the 3 bolts and engine mounting insulator sub-assembly RH.


Hide 47.REMOVE WIRE HARNESS CLAMP BRACKET

a.
A166737

Remove the bolt and wire harness clamp bracket.


Hide 48.INSTALL ENGINE HANGER

a.
A323351C02
0.875,0.469 1.719,0.292 1.719,0.292 2.667,0.479 false 0.813,1.427 1.656,1.25 1.656,1.25 2.667,1.458 false 1.625,0.094 1.938,0.25 0.313,0.156 10 false *1 1.542,1.01 1.74,1.198 0.198,0.188 10 true *2
*1 No. 1 Engine Hanger (Part No.12281-21090)
*2 Bolt (Part No. 91672-81025)


Install the 2 No. 1 engine hangers with the 2 bolts.

Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)


b.

Attach an engine sling device and hang the engine assembly with transaxle with a chain block.

NOTICE:
·

Pay attention to the angle of the sling device as the engine assembly or 2 No. 1 engine hangers may be damaged or deformed if the angle is incorrect.

·

Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.




Hide 11363A 49.REMOVE FLYWHEEL HOUSING SIDE COVER

a.
A309817C01
2.625,0.896 2.823,0.208 2.823,0.208 2.99,0.208 false 3.031,0.125 3.344,0.323 0.313,0.198 10 false *a
*a Protruding Portion


Push up the flywheel housing side cover as shown in the illustration to disengage the claw, and remove the flywheel housing side cover.


Hide 28100 50.REMOVE STARTER ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE STARTING>STARTER>REMOVAL

Hide 82121 51.REMOVE ENGINE WIRE

a.

Remove the engine wire from the engine assembly with transaxle.


Hide 30300 52.REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

Click hereDrivetrain>C50 MANUAL TRANSMISSION / TRANSAXLE>MANUAL TRANSAXLE ASSEMBLY>REMOVAL

Hide 31210 53.REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for C50)>REMOVAL

Hide 31250 54.REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for C50)>REMOVAL

Hide 13405 55.REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>REMOVAL

Hide 30500 56.REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

Hide 32101 57.REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>REMOVAL

Hide 58.INSTALL ENGINE TO ENGINE STAND

a.

Install the engine assembly to an engine stand.

NOTICE:
·

Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.

·

Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.




Hide 59.REMOVE ENGINE HANGER

a.

Remove the 2 bolts, 2 No. 1 engine hangers.