Removal (from 07/2011)

1NZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY (for Hatchback): REMOVAL

NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Service Precautions.

1. REMOVE ENGINE UNDER COVER LH

2. REMOVE ENGINE UNDER COVER RH

3. REMOVE FRONT WHEELS

4. DISCHARGE FUEL SYSTEM PRESSURE

Fuel System (for Hatchback)

5. DRAIN ENGINE COOLANT Service and Repair

6. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Removal (from 07/2011)

7. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) Service and Repair

8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Removal (from 07/2011)

9. REMOVE FRONT NO. 1 VENTILATOR SEAL Removal (from 07/2011)

10. REMOVE FRONT AIR SHUTTER SEAL RH Removal (from 07/2011)

11. REMOVE INNER COWL TOP TO COWL BRACE Removal (from 07/2011)

12. REMOVE OUTER COWL TOP PANEL Removal (from 07/2011)

13. REMOVE BATTERY

(a) Disconnect the cable from the battery terminal.

(b) Loosen the 2 nuts and remove the battery clamp.

(c) Remove the battery.

14. REMOVE BATTERY TRAY

15. REMOVE NO. 2 CYLINDER HEAD COVER

(a) Remove the 4 nuts and No. 2 cylinder head cover.

16. REMOVE AIR CLEANER ASSEMBLY

(a) Disengage the clamp and disconnect the fuel vapor feed hose assembly from the No. 1 air cleaner hose.

(b) Loosen the 2 hose clamps and disconnect the fuel vapor feed hose assembly from the No. 1 air cleaner hose and vacuum switching valve assembly.

(c) Disconnect the No. 2 fuel vapor feed hose from the intake manifold.

(d) Disengage the 2 clamps and disconnect the wire harness from the air cleaner cap sub-assembly and vacuum switching valve assembly.

(e) Disconnect the mass air flow meter connector.

(f) Disconnect the vacuum switching valve connector.

(g) Loosen the hose clamp and disconnect the No. 1 air cleaner hose from the throttle with motor body assembly.

(h) Disengage the 2 clamps and remove the air cleaner cap sub-assembly with No. 1 air cleaner hose.

(i) Remove the air cleaner element.

(j) Disengage the clamp and disconnect the wire harness from the air cleaner case.

(k) Remove the 2 bolts and the air cleaner case from the air cleaner bracket.

17. REMOVE AIR CLEANER BRACKET

(a) Disengage the clamp and disconnect the wire harness from the air cleaner bracket.

(b) Remove the 2 bolts and the air cleaner bracket.

18. REMOVE BATTERY CARRIER

(a) Disengage the 6 clamps and disconnect the wire harness from the battery carrier.

(b) Remove the 5 bolts and the battery carrier.

19. REMOVE FUEL VAPOR FEED HOSE ASSEMBLY

(a) Loosen the 2 hose clamps and remove the fuel vapor feed hose assembly.

20. DISCONNECT RADIATOR RESERVOIR TANK HOSE

(a) Disconnect the radiator reservoir tank hose from the water filler.

21. DISCONNECT NO. 3 RADIATOR HOSE

(a) Loosen the hose clamp and disconnect No. 3 radiator hose from the water filler.

22. DISCONNECT NO. 2 RADIATOR HOSE

(a) Loosen the hose clamp and disconnect No. 2 radiator hose from the water inlet.

23. REMOVE EFI FUEL PIPE CLAMP

(a) Remove the fuel pipe clamp.

24. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.

Text in Illustration

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, twist or turn 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. DISCONNECT OUTLET OIL COOLER HOSE (for Automatic Transaxle)

(a) Loosen the hose clamp and disconnect the oil cooler outlet hose.

26. DISCONNECT INLET OIL COOLER HOSE (for Automatic Transaxle)

(a) Loosen the hose clamp and disconnect the oil cooler inlet hose.

27. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Loosen the hose clamp and disconnect the union to check valve hose from the booster vacuum tube.

28. DISCONNECT OUTLET HEATER WATER HOSE A

(a) Loosen the hose clamp and disconnect outlet heater water hose A from the heater unit.

29. DISCONNECT INLET HEATER WATER HOSE A

(a) Loosen the hose clamp and disconnect inlet heater water hose A from the heater unit.

30. REMOVE FAN AND GENERATOR V BELT Removal (from 07/2011)

31. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Removal (from 07/2011)

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

(a) Disconnect the connector.

(b) Remove the 4 bolts and separate the compressor with pulley assembly.

HINT
Remove the compressor assembly together with the low and high pressure hoses, then suspend them from the body with a piece of rope.

33. DISCONNECT ENGINE WIRE

(a) for Automatic Transaxle:

(1) Disengage the clamp and disconnect the wire harness from the automatic transaxle.

(2) Remove the bolt and separate the wire harness from the automatic transaxle.

(b) Disengage the wire harness clamp and separate the wire harness.

(c) Pull up the lever and disconnect the connector of the engine control computer.

(d) Disengage the clamp and disconnect the wire harness.

(e) Disconnect the 2 connectors.

(f) Disengage the 2 claws and disconnect the wire harness from the engine room relay block.

(g) Disconnect the 2 connectors from the battery positive terminal.

(h) Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.

34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Removal (from 07/2011)

35. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Removal (from 07/2011)

36. REMOVE REAR CONSOLE BOX ASSEMBLY

Removal (from 07/2011)

37. REMOVE FRONT FLOOR CENTER BRACE Removal (from 07/2011)

38. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal (from 07/2011)

39. REMOVE EXHAUST PIPE GASKET Removal (from 07/2011)

40. REMOVE NO. 2 EXHAUST PIPE GASKET Removal (from 07/2011)

41. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

Removal (from 07/2011)

42. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle)

(a) Remove the flywheel housing under cover.

43. REMOVE TORQUE CONVERTER SETTING BOLT (for Automatic Transaxle)

(a) Hold the crankshaft with SST.

SST : 09960-10010

09962-01000

09963-01000

(b) Remove the 6 torque converter set bolts.

44. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal (from 07/2011)

45. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY Removal (from 07/2011)

46. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal (from 07/2011)

47. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Place the wooden blocks or plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transaxle.

Text in Illustration

NOTICE:
* Place the wooden blocks or plate lift attachments so that the front suspension crossmember sub-assembly is level.
* As the engine assembly with transaxle is very heavy, be sure to support it securely.
* To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine assembly.

(b) Remove the bolt, 2 nuts and the engine mounting insulator RH.

(d) Remove the 6 bolts, and remove the engine assembly with transaxle and the front suspension crossmember from the vehicle.

NOTICE:
When removing the engine, be careful not to damage any wire harnesses of the steering shaft.

48. INSTALL NO. 1 ENGINE HANGER

(a) Remove the bolt and the wire harness bracket.

(b) Install the 2 engine hangers with the 2 bolts, as shown in the illustration.

Text in Illustration

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

HINT

49. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember.

(b) Remove the through bolt from the engine moving control rod and remove the front suspension crossmember.

50. REMOVE NO. 1 IGNITION COIL Removal (from 07/2011)

51. REMOVE ENGINE WIRE

(a) Remove the 2 ground bolts.

(b) Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.

52. REMOVE VENTILATION HOSE

(a) Loosen the 2 hose clamps and remove the ventilation hose.

53. REMOVE WATER FILLER SUB-ASSEMBLY

(a) Loosen the hose clamp and disconnect radiator hose No. 1 from the cylinder head.

(b) Remove the 2 nuts and the water filler sub-assembly.

54. REMOVE INTAKE MANIFOLD

(a) Loosen the hose clamp and disconnect the union to connector tube hose from the booster vacuum tube.

(b) Loosen the hose clamp and disconnect the water by-pass hose from the cylinder head.

(c) Disconnect the water by-pass hose from the No. 1 water by-pass pipe.

(d) Remove the 3 bolts, 2 nuts and the intake manifold.

(e) Remove the gasket from the intake manifold.

55. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 4 bolts and the No. 1 exhaust manifold heat insulator.

56. REMOVE MANIFOLD SUPPORT BRACKET

(a) Remove the 3 bolts and the manifold support bracket.

57. REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts, 2 nuts and the exhaust manifold.

58. FIX ENGINE ASSEMBLY

(a) Using an engine sling device and a chain block, hold the engine assembly.

(b) To enable removal of the engine assembly, adjust the positions of the plate lift attachments and set them in place.

NOTICE:
* Set plate lift attachments so that the engine assembly with transaxle is level.
* Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
* To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine assembly.

(c) Use a belt with a tightening mechanism or a rope to secure the engine assembly with transaxle to the engine lifter.

NOTICE:
* Do not tighten the belt with a tightening mechanism or the rope any more than is necessary.
* Set the engine assembly with transaxle so that is horizontal.

59. REMOVE FLYWHEEL HOUSING SIDE COVER Removal

60. REMOVE STARTER ASSEMBLY Removal

61. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

(a) Remove the bolt and wire harness bracket from the automatic transaxle assembly.

(b) Remove the 7 bolts and the automatic transaxle assembly with torque converter.

62. REMOVE CONTROL CABLE BRACKET (for Manual Transaxle) Removal (from 07/2011)

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

(a) Hold the crankshaft with SST.

SST : 09960-10010

09962-01000

09963-01000

(b) Remove the 6 bolts, drive plate spacer FR, drive plate and ring gear sub-assembly and drive plate spacer RR.

64. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

(a) Remove the 7 bolts and the manual transaxle assembly.

65. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) Removal (from 07/2011)

66. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) Removal (from 07/2011)

67. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

(a) Hold the crankshaft with SST.

SST : 09960-10010

09962-01000

09963-01000

(b) Remove the 6 bolts and flywheel.

68. REMOVE INLET HEATER WATER HOSE A

(a) Disconnect heater water inlet hose A from the cylinder head.

69. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

(a) Remove the bolt, nut and the drive shaft heat insulator.

70. REMOVE ENGINE MOUNTING INSULATOR RH

HINT
Only perform this procedure when replacement of the engine mounting insulator RH is necessary.

(a) Remove the 3 bolts and engine mounting insulator RH.

71. REMOVE ENGINE MOUNTING INSULATOR LH

HINT
Only perform this procedure when replacement of the engine mounting insulator RH is necessary.

(a) Remove the 5 bolts and engine mounting insulator LH.