Removal

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:

REMOVAL

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (Removal)

2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FRONT FENDER APRON SEAL RH
6. DRAIN ENGINE OIL
7. DRAIN ENGINE COOLANT (Service and Repair)

8. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Using a 10 mm hexagon wrench, remove the drain plug and gasket. Drain automatic transaxle fluid.
(b) Install a new gasket and the drain plug.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
9. DRAIN MANUAL TRANSAXLE OIL
(a) Install a new gasket and the drain plug after draining transaxle oil.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
10. REMOVE BATTERY
11. REMOVE AIR CLEANER ASSEMBLY
12. REMOVE ENGINE NO.1 COVER SUB-ASSEMBLY
13. DISCONNECT RADIATOR HOSE INLET
14. DISCONNECT RADIATOR HOSE OUTLET
15. DISCONNECT OIL COOLER OUTLET HOSE NO.2
16. DISCONNECT OIL COOLER OUTLET HOSE NO.3
17. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET

(a) Remove the 3 bolts and the engine moving control rod w/bracket.
18. REMOVE ENGINE MOUNTING STAY NO.2 RH
19. REMOVE ENGINE MOUNTING BRACKET NO.2 RH
20. REMOVE FAN AND GENERATOR V BELT (Removal)

21. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1

(a) Disconnect the oil reservoir to the pump hose No.1.
22. DISCONNECT RETURN TUBE SUB-ASSEMBLY

(a) Disconnect the return tube sub-assembly.
23. DISCONNECT UNION TO CONNECTOR TUBE HOSE
24. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T)
25. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T)
26. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T)
27. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (M/T)
(a) Remove the bolt and flexible hose.
(b) Remove the 2 bolts and clutch release cylinder.
28. DISCONNECT HEATER INLET WATER HOSE
29. DISCONNECT HEATER OUTLET WATER HOSE
30. DISCONNECT FUEL TUBE SUB-ASSEMBLY (Removal)

31. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and passenger side J/B.
(b) Disconnect the engine wire from the engine room J/B.

(1) Remove the nut and separate the wire harness.
(2) Using a screwdriver, unlock the engine room J/B. Pull the engine room J/B upward.

(3) Disconnect the engine wire connectors.
(c) Pull out the engine wire.

(d) Disconnect the B terminal of the generator.
(e) Remove the body ground.
32. REMOVE ENGINE WIRE NO.2

(a) Remove the starter connector.
(b) Remove the nut and disconnect terminal 30 of the starter.
33. REMOVE GENERATOR ASSEMBLY
34. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

HINT: Hang up the hoses instead of detaching them.

35. REMOVE FRONT EXHAUST PIPE ASSEMBLY
36. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
(a) Using a 6 mm socket hexagon wrench, fix the stud bolt.
(b) Remove the nut and disconnect the stabilizer link.
37. REMOVE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

38. REMOVE FRONT AXLE SHAFT LH NUT

(a) Using SST and a hammer, strike the lock nut covering to remove it.
SST: 09930-00010

- Set the drive shaft's groove so that it faces up. Then use the SST and hammer.
- Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged.
- Do not sharpen the tip of the SST.

(b) Using a 30 mm socket wrench, remove the lock nut.
39. REMOVE FRONT AXLE SHAFT RH NUT

HINT: Use the same procedures described for the LH side.

40. REMOVE SPEED SENSOR FRONT LH
(a) Remove the bolt and disconnect the speed sensor from the steering knuckle.

NOTE: Keep the speed sensor tip and connection free of foreign matter.

41. REMOVE SPEED SENSOR FRONT RH

HINT: Use the same procedures described for the LH side.

42. DISCONNECT TIE ROD ASSEMBLY LH

(a) Remove the cotter pin and castle nut.
(b) Using SST, disconnect the tie rod end from the steering knuckle.
SST: 09628-62011

NOTE: Be careful not to damage the cover of the ball joint.

43. DISCONNECT TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

44. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH

(a) Remove the bolt and 2 nuts, as shown in the illustration.
(b) Using a plastic hammer, disconnect the drive shaft from the axle hub.
45. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Use the same procedures described for the LH side.

46. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (A/T)

(a) Fix the crankshaft and remove the 6 setting bolts.
47. REMOVE STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) Loosen the sliding yoke bolt.

(b) Place matchmarks on the intermediate shaft and control valve shaft.
(c) Remove the bolt and the steering intermediate shaft.

(d) To prevent the steering wheel from rotating, fix the wheel with the seat belt.

NOTE: If the steering wheel is not fixed, the spiral cable will be damaged.

48. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.
(b) Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.

(c) Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.
(d) Carefully remove the engine assembly from the vehicle.

(e) Install the 2 engine hangers as shown in the illustration.
Parts No.:

Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)
(f) Using a chain block and an engine sling device, hang the engine assembly.
49. REMOVE VANE PUMP ASSEMBLY

(a) Disconnect the PS oil pressure switch connector.
(b) Remove the 2 bolts and vane pump from the engine.
50. REMOVE FRONT FRAME ASSEMBLY

(a) A/T:
Remove the nut from the engine mounting insulator LH.

(b) M/T:
Remove the bolt from the engine mounting insulator LH.

(d) Remove the bolt from the engine mounting insulator FR.

(e) M/T:
Remove the bolt from the engine lateral control rod.
(f) Raise the engine assembly and separate the front frame.
51. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (Removal)

52. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (Removal)

53. REMOVE STARTER ASSEMBLY (Removal)

54. SEPARATE AUTOMATIC TRANSAXLE ASSEMBLY (Removal)

55. SEPARATE MANUAL TRANSAXLE ASSEMBLY (Removal)

56. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY

(a) Using SST, fix the crankshaft.
SST: 09960-10010
09962-01000
09963-01000

(b) Remove the 8 bolts, rear spacer, drive plate and front spacer.
57. REMOVE CLUTCH COVER ASSEMBLY (Disassembly)

58. REMOVE CLUTCH DISC ASSEMBLY (Disassembly)

59. REMOVE FLYWHEEL SUB-ASSEMBLY

(a) Using SST, fix the crankshaft.
SST: 09960-10010
09962-01000
09963-01000

(b) Remove the 8 bolts, rear spacer and flywheel.
60. INSTALL ENGINE STAND
61. REMOVE INTAKE MANIFOLD

(a) Remove the 5 bolts, 2 nuts, intake manifold and gasket.
62. REMOVE VENTILATION HOSE
63. REMOVE VENTILATION HOSE NO.2
64. REMOVE ENGINE WIRE
65. REMOVE INTAKE MANIFOLD INSULATOR NO.1
66. REMOVE OIL LEVER GAGE SUB-ASSEMBLY
67. REMOVE OIL LEVEL GAGE GUIDE
68. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
69. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Remove the bolt, nut and manifold stay.

(b) Remove the bolt, nut and No. 2 manifold stay.

(c) Remove the 5 nuts, exhaust manifold converter and gasket.
70. REMOVE WATER INLET
71. REMOVE THERMOSTAT
72. REMOVE IGNITION COIL ASSEMBLY
73. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY ()

74. REMOVE DRIVE SHAFT BEARING BRACKET
75. REMOVE ENGINE MOUNTING BRACKET RH
76. REMOVE FUEL DELIVERY PIPE W/INJECTOR (Removal)

77. REMOVE WATER BY-PASS PIPE NO.1
78. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Remove the engine oil pressure switch assembly.
79. REMOVE KNOCK SENSOR
(a) Disconnect the sensor connector.
(b) Remove the nut and sensor.
80. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
81. REPLACE PARTIAL ENGINE ASSEMBLY