1ZR-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>1ZR-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 11212 12.REMOVE NO. 2 CYLINDER HEAD COVER

a.
A307202C01
0,0 0,0 false
V100136

Disengage the 2 rear clips first
V100135

Disengage the 2 front clips next


Lift the rear of the No. 2 cylinder head cover to disengage the 2 rear clips. Lift the front of the No. 2 cylinder head cover to disengage the 2 front clips and remove the No. 2 cylinder head cover.

NOTICE:

Attempting to disengage both front and rear clips at the same time may cause the No. 2 cylinder head cover to break.



Hide 17705 13.REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>THROTTLE BODY>REMOVAL

Hide 17701 14.REMOVE AIR CLEANER CASE SUB-ASSEMBLY

a.
A287978

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


b.
A289012

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


c.

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


Hide 15.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 16.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 17.DISCONNECT NO. 1 RADIATOR HOSE

a.
A285508

Disconnect the breather plug hose from the clamp.


b.
A154266

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


Hide 16572D 18.DISCONNECT NO. 2 RADIATOR HOSE

a.
A154267

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


Hide 33820B 19.SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

a.
C176617C02
1.292,0.458 1.5,0.167 1.5,0.167 1.625,0.167 true 2.615,1.115 2.823,0.823 2.823,0.823 2.948,0.823 true 1.677,0.094 1.99,0.25 0.313,0.156 10 false *1 3,0.76 3.25,0.979 0.25,0.219 10 false *2
*1 No. 1 Transmission Control Cable Bracket
*2 Control Shaft Lever


Remove the nut and separate the transmission control cable assembly from the control shaft lever.


b.

Remove the clip and separate the transmission control cable assembly from the No. 1 transmission control cable bracket.


Hide 20.DISCONNECT OIL COOLER HOSE

a.
A325221

Slide the 2 clips and disconnect the 2 oil cooler hoses from the oil cooler tube.


Hide 23826 21.DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

a.
A177489

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


Hide 44774 22.DISCONNECT UNION TO CONNECTOR TUBE HOSE

a.
A312357

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


Hide 87246 23.DISCONNECT HEATER WATER OUTLET HOSE

a.
A325223

Slide the clip and disconnect the heater water outlet hose from the No. 1 water by-pass pipe.


Hide 87245 24.DISCONNECT HEATER WATER INLET HOSE

Click hereVehicle Interior>HEATING / AIR CONDITIONING>AIR CONDITIONING UNIT>REMOVAL

Hide 23901 25.DISCONNECT FUEL TUBE SUB-ASSEMBLY

a.
A203501

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 of 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 27.REMOVE GENERATOR ASSEMBLY

Click herePower Source / Network>1ZR-FE BATTERY / CHARGING>GENERATOR>REMOVAL

Hide 88310 28.SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY

a.
E278641

Disconnect the connector.


b.

Disengage the clamp.


c.
E278643C05
0,0 0,0 false
V100135

Bolt
V100136

Nut


Remove the 2 bolts and 2 nuts.


d.
E278645

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

HINT:

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



e.

Separate the compressor assembly with pulley from the engine assembly.


Hide 29.DISCONNECT WIRE HARNESS

a.
A285510

Pull up the lever and disconnect the ECM connector.


b.

Disconnect the wire harness clamp.


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 and disconnect the wire harness from the engine room relay block and junction block assembly.


g.
A327081

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


h.

Disconnect all the wire harnesses and connectors.

HINT:

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



Hide 45259A 30.REMOVE COLUMN HOLE COVER SILENCER SHEET

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL

Hide 45260 31.SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL

Hide 45025D 32.SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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

Hide 17410 33.REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

Click hereEngine / Hybrid System>1ZR-FE INTAKE / EXHAUST>EXHAUST MANIFOLD>REMOVAL

Hide 11361J 35.REMOVE FLYWHEEL HOUSING UNDER COVER

a.
C118502

Remove the flywheel housing under cover from the stiffening crankcase assembly.


Hide 32101A 36.REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click hereDrivetrain>U340E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

Hide 51201 37.REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>REMOVAL

Hide 38.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.
A310978

Remove the bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH.


d.
A325224

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

HINT:

When removing the through bolt, keep the nut from rotating.



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 39.REMOVE FRONT ENGINE MOUNTING INSULATOR

HINT:

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


a.
A325225

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 40.REMOVE REAR ENGINE MOUNTING INSULATOR

HINT:

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


a.
A325226

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


Hide 12372A 41.REMOVE ENGINE MOUNTING INSULATOR LH

HINT:

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


a.
A325227

Remove the 4 bolts and engine mounting insulator LH.


Hide 12305 42.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.
A310983

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


Hide 43.REMOVE WIRE HARNESS CLAMP BRACKET

a.
A312729

Disengage the 3 clamps and remove the bolt and wire harness clamp bracket.


Hide 44.INSTALL ENGINE HANGER

a.
A177451C01
1.073,1.49 1.688,1.677 1.688,1.677 2.625,1.177 true 1.854,0.573 2.031,0.573 2.031,0.573 2.573,0.833 true 0.76,0.781 0.563,0.781 false 0.385,0.677 0.698,0.875 0.313,0.198 10 *1 1.677,0.521 1.99,0.719 0.313,0.198 10 *2 1.594,1.74 1.906,1.938 0.313,0.198 10 *3
*1 No. 1 Engine Hanger (Part No.12281-37021)
*2 No. 2 Engine Hanger (Part No.12282-37011)
*3 Bolt (Part No. 91552-81050)


Install the No. 1 engine hanger and No. 2 engine hanger 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 a chain block.

NOTICE:
·

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

·

Do not perform any procedure while the engine assembly with 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 45.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 46.REMOVE STARTER ASSEMBLY

Click hereEngine / Hybrid System>1ZR-FE STARTING>STARTER>REMOVAL

Hide 82121 47.REMOVE ENGINE WIRE

a.

Remove the engine wire from the engine assembly with transaxle.


Hide 32101 49.REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click hereEngine / Hybrid System>1ZR-FE ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>REMOVAL

Hide 50.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 51.REMOVE ENGINE HANGER

a.

Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.