Removal and Installation

PARTIAL ENGINE ASSEMBLY (2AZ-FE)
REPLACEMENT





NOTICE: When disconnecting the battery negative terminal, initialize the system(s) shown after the terminal is reconnected.

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE FRONT FENDER APRON SEAL RH
7. REMOVE ENGINE COVER SUB-ASSEMBLY NO.1
8. DRAIN ENGINE COOLANT
9. DRAIN AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE)
10. DRAIN MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE)
11. DISCONNECT RADIATOR HOSE INLET
12. DISCONNECT RADIATOR HOSE OUTLET
13. DISCONNECT OIL COOLER INLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
14. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
15. REMOVE RADIATOR ASSEMBLY
16. REMOVE AIR CLEANER ASSEMBLY
a. Remove the air cleaner cap.
b. Remove the air cleaner filter element.





c. Disconnect the clamp of the engine wire.
d. Remove the 3 bolts from the air cleaner case.
e. Disconnect the air cleaner case from the air cleaner inlet No. 1.
17. REMOVE BATTERY
18. REMOVE BATTERY TRAY





19. REMOVE BATTERY CARRIER
a. Disconnect the clamp of the engine wire.
b. Remove the 4 bolts, then remove the battery carrier.
20. DISCONNECT FUEL TUBE SUB-ASSEMBLY
SST 09268-21010





21. DISCONNECT UNION TO CONNECTOR TUBE HOSE
a. Disconnect the union to connector tube hose from the booster vacuum tube.





22. DISCONNECT HEATER WATER INLET HOSE A
a. Disconnect the heater water inlet hose from the air conditioner tube.





23. DISCONNECT HEATER WATER OUTLET HOSE A(FROM HEATER UNIT)
a. Disconnect the heater water outlet hose from the air conditioner tube.
24. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (AUTOMATIC TRANSAXLE)
25. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (MANUAL TRANSAXLE)
26. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (MANUAL TRANSAXLE)
27. REMOVE FAN AND GENERATOR V-BELT
SST 09249-63010
28. REMOVE GENERATOR ASSEMBLY
29. SEPARATE W/PULLEY COMPRESSOR ASSEMBLY

HINT: Separate the compressor together with the low pressure and high pressure hoses, then secure it to the vehicle side using a rope.

30. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
31. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from the ECM and junction block.
b. Pull out the engine wire.
c. Remove the engine room relay block cover.





d. Remove the 2 claws and 2 connectors, and push the engine wire harness up.





e. Remove the 2 clamps of the engine wire.





f. Remove the nut from the battery positive terminal to disconnect the engine wire.





g. Remove the bolt, then disconnect the ground terminal.
32. REMOVE EXHAUST PIPE ASSEMBLY FRONT
33. REMOVE COLUMN HOLE COVER SILENCER SHEET
34. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2
35. REMOVE FRONT AXLE HUB LH NUT
SST 09930-00010
36. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010

HINT: Perform the same procedure as above on the opposite side.

37. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
38. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

39. SEPARATE SPEED SENSOR FRONT LH
40. SEPARATE SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

41. SEPARATE TIE ROD END SUB-ASSEMBLY LH
SST 09628-00011
42. SEPARATE TIE ROD END SUB-ASSEMBLY RH
SST 09628-00011

HINT: Perform the same procedure as above on the opposite side.

43. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
44. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Perform the same procedure as above on the opposite side.

45. SEPARATE FRONT AXLE ASSEMBLY LH
46. SEPARATE FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.





47. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Disconnect the oil reservoir to pump hose No. 1.





b. Disconnect the return tube.
c. Set the engine lifter.





d. Remove the bolt and 2 nuts, then separate the engine mounting bracket No. 2 RH.





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





f. Remove the 8 bolts and front suspension member brace rear RH and LH.





g. Remove the 2 bolts and 2 nuts shown in the illustration.
h. Carefully remove the engine with transaxle from the vehicle.





i. Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)





Parts No.

j. Attach the sling device and hang the engine with the chain block.
48. SEPARATE VANE PUMP ASSEMBLY





49. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a. Remove the through bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR.





b. Remove the through bolt, then separate the engine mounting insulator RR from the engine mounting bracket RR.
c. Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
50. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)
51. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
52. REMOVE STARTER ASSEMBLY
53. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (AUTOMATIC TRANSAXLE)
54. REMOVE MANUAL TRANSAXLE ASSEMBLY (MANUAL TRANSAXLE)
55. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSAXLE)
56. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSAXLE)
57. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSAXLE)
SST 09213-54015 (91651-60855), 09330-00021
58. REMOVE FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSAXLE)
SST 09213-54015 (91651-60855, (09330-00021





59. REMOVE DRIVE SHAFT BEARING BRACKET
a. Remove the 3 bolts and drive shaft bearing bracket.
60. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
61. REMOVE OIL LEVEL GAGE GUIDE
62. REMOVE MANIFOLD STAY
63. REMOVE MANIFOLD STAY NO.2
64. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
65. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
66. REMOVE WATER INLET
67. REMOVE THERMOSTAT





68. REMOVE WATER BYPASS PIPE NO.1
a. Remove the bolt and 2 nuts, then remove the water bypass pipe.
b. Remove the gasket from the cylinder block.
69. REMOVE INTAKE MANIFOLD
70. REMOVE INTAKE MANIFOLD INSULATOR NO.1
71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
72. REMOVE IGNITION COIL ASSEMBLY
73. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
74. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
75. REMOVE KNOCK SENSOR





76. REMOVE RADIO SETTING CONDENSER
a. Remove the bolt and condenser.
77. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
78. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
SST 09817-33190
79. REPLACE PARTIAL ENGINE ASSEMBLY
80. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
SST 09817-33190
81. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY





82. INSTALL RADIO SETTING CONDENSER
a. Install the condenser with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
83. INSTALL KNOCK SENSOR
84. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
85. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
86. INSTALL IGNITION COIL ASSEMBLY
87. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
88. INSTALL INTAKE MANIFOLD INSULATOR NO.1
89. INSTALL INTAKE MANIFOLD





90. INSTALL WATER BYPASS PIPE NO.1
a. Install a new gasket and the water bypass pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
91. INSTALL THERMOSTAT
92. INSTALL WATER INLET
93. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
94. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
95. INSTALL MANIFOLD STAY NO.2
96. INSTALL MANIFOLD STAY
97. INSTALL OIL LEVEL GAGE GUIDE
98. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY





99. INSTALL DRIVE SHAFT BEARING BRACKET
a. Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
100. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSAXLE)
SST 09213-54015 (91651-60855), 09330-00021
101. INSTALL FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSAXLE)
SST 09213-54015 (91651-60855), 09330-00021
102. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSAXLE)
SST 09301-00220
103. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSAXLE)
104. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (AUTOMATIC TRANSAXLE)
105. INSTALL MANUAL TRANSAXLE ASSEMBLY (MANUAL TRANSAXLE)
106. INSTALL STARTER ASSEMBLY
107. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
108. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
109. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.





b. Install the through bolt, which is used to secure the engine mounting insulator RR, into the engine mounting bracket RR.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)





c. Install the bolt, which is used to secure the engine mounting insulator FR, into the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
110. INSTALL VANE PUMP ASSEMBLY
111. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifter.





b. Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.





c. Install the engine mounting insulator LH with the through bolt and nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)





d. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





e. Tighten the 2 bolts and 2 nuts.
Torque:
45 Nm (459 kgf-cm, 33 ft. lbs.) for bolt
133 Nm (1,356 kgf-cm, 98 ft. lbs.) for nut





f. Install the front suspension member brace rear RH and LH with the 8 bolts.
Torque:
133 Nm (1,356 kgf-cm, 98 ft. lbs.) for bolt A
80 Nm (816 kgf-cm, 59 ft. lbs.) for bolt B

NOTICE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.

g. Connect the return tube.
h. Connect the oil reservoir to pump hose No. 1.
112. INSTALL FRONT AXLE ASSEMBLY LH
113. INSTALL FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

114. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
115. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Perform the same procedure as above on the opposite side.

116. INSTALL TIE ROD END SUB-ASSEMBLY LH
117. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

118. INSTALL SPEED SENSOR FRONT LH
119. INSTALL SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

120. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
121. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

122. INSTALL FRONT AXLE HUB LH NUT
123. INSTALL FRONT AXLE HUB RH NUT

HINT: Perform the same procedure as above on the opposite side.

124. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2
125. INSTALL COLUMN HOLE COVER SILENCER SHEET
126. INSTALL EXHAUST PIPE ASSEMBLY FRONT
127. CONNECT ENGINE WIRE
128/ INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
129. INSTALL W/PULLEY COMPRESSOR ASSEMBLY
130. INSTALL GENERATOR ASSEMBLY
131. INSTALL FAN AND GENERATOR V-BELT
SST 09249-63010
132. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (MANUAL TRANSAXLE)
133. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (AUTOMATIC TRANSAXLE)
134. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (MANUAL TRANSAXLE)
135. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
136. CONNECT HEATER WATER INLET HOSE A
137. CONNECT UNION TO CONNECTOR TUBE HOSE
138. CONNECT FUEL TUBE SUB-ASSEMBLY





139. INSTALL BATTERY CARRIER
a. Install the battery carrier with the 4 bolts.
Torque: 12.8 Nm (131 kgf-cm, 9 ft. lbs.)
b. Connect the clamp of the engine wire.
140. INSTALL BATTERY TRAY
141. INSTALL BATTERY





142. INSTALL AIR CLEANER ASSEMBLY
a. Connect the air cleaner case to the air cleaner inlet No. 1.
b. Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
c. Connect the clamp of the engine wire.
d. Install the air cleaner filter element.
e. Install the air cleaner cap.
143. INSTALL RADIATOR ASSEMBLY
144. CONNECT OIL COOLER OUTLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
145. CONNECT OIL COOLER INLET TUBE NO.1 (AUTOMATIC TRANSAXLE)
146. CONNECT RADIATOR HOSE OUTLET
147. CONNECT RADIATOR HOSE INLET
148. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
149. BLEED POWER STEERING FLUID
150. ADD AUTOMATIC TRANSAXLE FLUID (AUTOMATIC TRANSAXLE)
151. ADD MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE)
152. INSPECT MANUAL TRANSAXLE OIL (MANUAL TRANSAXLE)
153. ADD ENGINE COOLANT
154. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
155. CHECK FOR FLUID LEAKAGE
156. CHECK FOR ENGINE COOLANT LEAKAGE
157. CHECK FOR FUEL LEAKAGE
158. CHECK FOR EXHAUST GAS LEAKAGE
159. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
160. CHECK ABS SPEED SENSOR SIGNAL
161. CHECK IGNITION TIMING
SST 09843-18040
162. INSPECT ENGINE IDLING SPEED
SST 09843-18030
163. INSPECT CO/HC
164. INSTALL ENGINE COVER SUB-ASSEMBLY NO.1
165. INSTALL FRONT FENDER APRON SEAL RH
166. INSTALL ENGINE UNDER COVER LH
167. INSTALL ENGINE UNDER COVER RH