2ZR-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.


NOTICE:

for Manual Transaxle:

When the manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder assembly and a new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release with bearing cylinder assembly to return to its original position. Dust from the moving section may damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.


PROCEDURE

Hide 1. PRECAUTION

NOTICE:

After turning the engine 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

Hide 3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

Hide 4. SECURE STEERING WHEEL

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

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)

Hide 12.DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

Hide 11212 13.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 14.REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Hide 15.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 28800 16.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 17.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 18.DISCONNECT NO. 1 RADIATOR HOSE

a.
A285508

for CVT:

i.

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 19.DISCONNECT NO. 2 RADIATOR HOSE

a.
A154267

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


Hide 33820B 20.SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

a.
C274882N02
2.542,1.219 2.698,1.417 0.156,0.198 10 A 2.99,0.552 3.146,0.75 0.156,0.198 10 B 1.885,0.49 2.042,0.688 0.156,0.198 10 A 2.375,0.052 2.531,0.25 0.156,0.198 10 B

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


b.

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


Hide 33820B 21.SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)

a.
C292819

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 31418 22.DISCONNECT CLUTCH HOSE (for Manual Transaxle)

a.
A308255

Using a 10 mm union nut wrench, disconnect the clutch hose from the clutch release cylinder to flexible hose tube.


b.

Remove the clip and disconnect the clutch hose.


Hide 23826 23.DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

a.
A234727

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


Hide 44774 24.DISCONNECT UNION TO CONNECTOR TUBE HOSE

a.
A325119

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


Hide 87246 25.DISCONNECT HEATER WATER OUTLET HOSE (for CVT)

a.
A235883

Slide the clip and disconnect the heater water outlet hose from the air conditioner unit assembly.


b.

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


Hide 87246 26.DISCONNECT HEATER WATER OUTLET HOSE (for Manual Transaxle)

a.
A235951

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


Hide 87245 27.DISCONNECT HEATER WATER INLET HOSE

Hide 23901 28.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 30.REMOVE GENERATOR ASSEMBLY

Hide 88310 31.SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY

a.
E278641

Disconnect the connector.


b.

Disengage the clamp.


c.
E278643C04
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 32.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.

for Manual Transaxle:

i.
A241120

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



h.
A289328

for CVT:

i.

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



i.

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 33.REMOVE COLUMN HOLE COVER SILENCER SHEET

Hide 45260 34.SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Hide 45025D 35.SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Hide 17410 36.REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

Hide 11361J 38.REMOVE FLYWHEEL HOUSING UNDER COVER

a.
C118502

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


Hide 32101A 39.REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)

Hide 51201 40.REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Hide 41.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.
A325590

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


d.
A312354C01
0.083,0.042 0.458,0.281 0.375,0.24 12 false *A 0.083,2.313 0.458,2.552 0.375,0.24 12 false *B
*A for Manual Transaxle
*B for CVT


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 42.REMOVE FRONT ENGINE MOUNTING INSULATOR

HINT:

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


a.
A312355C01
0.073,0.052 0.448,0.292 0.375,0.24 12 false *A 0.083,2.323 0.458,2.563 0.375,0.24 12 false *B
*A for Manual Transaxle
*B for CVT


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 43.REMOVE REAR ENGINE MOUNTING INSULATOR

HINT:

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


a.
A312352C01
0.063,0.052 0.438,0.292 0.375,0.24 12 false *A 0.073,2.313 0.448,2.552 0.375,0.24 12 false *B
*A for Manual Transaxle
*B for CVT


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


Hide 12372A 44.REMOVE ENGINE MOUNTING INSULATOR LH

HINT:

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


a.
A311184

Remove the 4 bolts and engine mounting insulator LH.


Hide 12305 45.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.
A325591

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


Hide 46.REMOVE WIRE HARNESS CLAMP BRACKET

a.
A312729

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


Hide 47.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 transaxle 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 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 16282 48.DISCONNECT NO. 5 WATER BY-PASS HOSE (for CVT)

Hide 87245 49.REMOVE HEATER WATER INLET HOSE

a.

Slide the clip and remove the heater water inlet hose from the cylinder head sub-assembly.


Hide 11363A 50.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 51.REMOVE STARTER ASSEMBLY

Hide 82121 52.REMOVE ENGINE WIRE

a.

Remove the engine wire from the engine assembly with transaxle.


Hide 30300 53.REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

Hide 31482 54.REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

Hide 31407B 55.REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

Hide 31400 56.REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

Hide 31483 57.REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)

Hide 31210 58.REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

Hide 31250 59.REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

Hide 13405 60.REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

Hide 30400 61.REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

Hide 32101 62.REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

Hide 63.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 64.REMOVE ENGINE HANGER

a.

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