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
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
2. DISCHARGE FUEL SYSTEM PRESSURE
3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
4. SECURE STEERING WHEEL
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
6.REMOVE FRONT WHEELS
51442C 7.REMOVE ENGINE UNDER COVER LH
Remove the 2 bolts, 4 screws, 3 clips and engine under cover LH.
51441C 8.REMOVE ENGINE UNDER COVER RH
Remove the 3 bolts, 4 screws, 3 clips and engine under cover RH.
9.DRAIN ENGINE COOLANT
10.DRAIN ENGINE OIL
11.DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)
12.DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)
11212 13.REMOVE NO. 2 CYLINDER HEAD COVER
Disengage the 2 rear clips first | |
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.
17705 14.REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
15.REMOVE AIR CLEANER CASE SUB-ASSEMBLY
Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
Disconnect the wire harness clamp from the air cleaner case sub-assembly.
Remove the 3 bolts and air cleaner case sub-assembly.
28800 16.REMOVE BATTERY
Loosen the nut, and disconnect the cable from the positive (+) battery terminal.
Remove the bolt, nut and battery clamp sub-assembly.
Remove the battery and battery tray from the battery carrier.
*1 | Battery Clamp Bolt |
*2 | Battery Carrier Support |
Remove the battery clamp bolt from the battery carrier support.
74411 17.REMOVE BATTERY CARRIER
Disconnect the 2 wire harness clamps from the battery carrier.
Remove the 2 bolts and disconnect the radiator pipe from the battery carrier.
Remove the 4 bolts and battery carrier.
16571C 18.DISCONNECT NO. 1 RADIATOR HOSE
for CVT:
Disconnect the breather plug hose from the clamp.
Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.
16572D 19.DISCONNECT NO. 2 RADIATOR HOSE
Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
33820B 20.SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
Remove the 2 clips (A) and separate the transmission control cable assembly from the manual transaxle assembly.
Remove the 2 clips (B) and separate the transmission control cable assembly from the control cable bracket assembly.
33820B 21.SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)
Remove the nut and separate the transmission control cable assembly from the control shaft lever.
Remove the clip and separate the transmission control cable assembly from the No. 1 transmission control cable bracket.
31418 22.DISCONNECT CLUTCH HOSE (for Manual Transaxle)
Using a 10 mm union nut wrench, disconnect the clutch hose from the clutch release cylinder to flexible hose tube.
Remove the clip and disconnect the clutch hose.
23826 23.DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).
44774 24.DISCONNECT UNION TO CONNECTOR TUBE HOSE
Slide the clip and disconnect the union to connector tube hose from the air tube.
87246 25.DISCONNECT HEATER WATER OUTLET HOSE (for CVT)
Slide the clip and disconnect the heater water outlet hose from the air conditioner unit assembly.
Slide the clip and disconnect the heater water outlet hose from the No. 1 water by-pass pipe.
87246 26.DISCONNECT HEATER WATER OUTLET HOSE (for Manual Transaxle)
Slide the clip and disconnect the heater water outlet hose from the No. 1 water by-pass pipe.
87245 27.DISCONNECT HEATER WATER INLET HOSE
23901 28.DISCONNECT FUEL TUBE SUB-ASSEMBLY
Disengage the claw and remove the No. 1 fuel pipe clamp.
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.
16361A 29.REMOVE V-RIBBED BELT
27020 30.REMOVE GENERATOR ASSEMBLY
88310 31.SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY
Disconnect the connector.
Disengage the clamp.
Bolt | |
Nut |
Remove the 2 bolts and 2 nuts.
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.
Separate the compressor assembly with pulley from the engine assembly.
32.DISCONNECT WIRE HARNESS
Pull up the lever and disconnect the ECM connector.
Disconnect the wire harness clamp.
Remove the No. 1 engine room relay block cover from the engine room relay block and junction block assembly.
Remove the 2 nuts from the engine room relay block and junction block assembly.
Disconnect the 3 wire harness connectors.
Disengage the 2 claws and disconnect the wire harness from the engine room relay block and junction block assembly.
for Manual Transaxle:
Remove the bolt and disconnect the No. 3 engine wire from the manual transaxle assembly.
for CVT:
Remove the bolt and disconnect the clamp and No. 3 engine wire from the continuously variable transaxle assembly.
Disconnect all the wire harnesses and connectors.
- HINT:
-
Make sure that no wire harness is connected between the vehicle body and engine assembly.
45259A 33.REMOVE COLUMN HOLE COVER SILENCER SHEET
45260 34.SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
45025D 35.SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
17410 36.REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)
37.REMOVE DRIVE SHAFT ASSEMBLY
11361J 38.REMOVE FLYWHEEL HOUSING UNDER COVER
Remove the flywheel housing under cover from the stiffening crankcase assembly.
32101A 39.REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)
51201 40.REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
41.REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
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.
Remove the center engine mounting member sub-assembly.
Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>REMOVAL
Remove the bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH.
*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.
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.
12361A 42.REMOVE FRONT ENGINE MOUNTING INSULATOR
- HINT:
-
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
*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.
12371A 43.REMOVE REAR ENGINE MOUNTING INSULATOR
- HINT:
-
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
*A | for Manual Transaxle |
*B | for CVT |
Remove the through bolt and rear engine mounting insulator from the rear engine mounting bracket.
12372A 44.REMOVE ENGINE MOUNTING INSULATOR LH
- HINT:
-
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
Remove the 4 bolts and engine mounting insulator LH.
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.
Disengage the clamp to separate the reserve hose.
Remove the reserve tank cap sub-assembly.
Remove the 3 bolts and radiator reserve tank assembly.
Remove the 3 bolts and engine mounting insulator sub-assembly RH.
46.REMOVE WIRE HARNESS CLAMP BRACKET
Disengage the 3 clamps and remove the bolt and wire harness clamp bracket.
47.INSTALL ENGINE HANGER
*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)
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.
16282 48.DISCONNECT NO. 5 WATER BY-PASS HOSE (for CVT)
87245 49.REMOVE HEATER WATER INLET HOSE
Slide the clip and remove the heater water inlet hose from the cylinder head sub-assembly.
11363A 50.REMOVE FLYWHEEL HOUSING SIDE COVER
*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.
28100 51.REMOVE STARTER ASSEMBLY
82121 52.REMOVE ENGINE WIRE
Remove the engine wire from the engine assembly with transaxle.
30300 53.REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
31482 54.REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transaxle)
31407B 55.REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
31400 56.REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)
31483 57.REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)
31210 58.REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)
31250 59.REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)
13405 60.REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
30400 61.REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)
32101 62.REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)
63.INSTALL ENGINE TO ENGINE STAND
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.
64.REMOVE ENGINE HANGER
Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.