Removal

2AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

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

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

2. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.

3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

4. REMOVE FRONT WHEELS

5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

6. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

7. REMOVE ENGINE UNDER COVER LH

8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

9. REMOVE ENGINE UNDER COVER RH

10. REMOVE FRONT FENDER APRON SEAL LH

11. REMOVE FRONT FENDER APRON SEAL RH

12. DRAIN ENGINE OIL Replacement

13. DRAIN ENGINE COOLANT Testing and Inspection

14. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Replacement

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

16. DRAIN BRAKE FLUID (for Manual Transaxle) Removal

17. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Lift the rear of the engine cover to detach the cover from the 2 pins, and then lift the front of the engine cover to detach the cover from the pin and remove the engine cover.

NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

18. REMOVE INLET AIR CLEANER ASSEMBLY

(a) Remove the 2 bolts and inlet air cleaner assembly.

19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for PZEV) Removal

20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (except PZEV) Removal

21. REMOVE AIR CLEANER FILTER ELEMENT

22. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Disconnect the wire harness clamp.

(b) Remove the 3 bolts and air cleaner case sub-assembly.

23. REMOVE BATTERY

(a) Loosen the nut, and separate the positive (+) battery terminal.

(b) Loosen the nut, and remove the bolt and battery clamp.

(c) Remove the battery and battery tray.

24. DISCONNECT INLET RADIATOR HOSE

(a) Disconnect the wire harness clamp.

(b) Disconnect the inlet radiator hose.

25. DISCONNECT OUTLET RADIATOR HOSE

(a) Disconnect the outlet radiator hose.

26. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

27. DISCONNECT OUTLET HEATER WATER HOSE

(a) for Manual Transaxle:

(1) Disconnect the outlet heater water hose.

(b) for Automatic Transaxle:

(1) Disconnect the 3 outlet heater water hoses.

28. DISCONNECT ENGINE WIRE

(a) Remove the nut, and disconnect the 3 engine wire connectors from the engine room relay block.

(b) Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

(c) Disconnect the engine wire clamp.

(d) Remove the bolt and separate the ground cable.

(e) Remove the bolt and separate the ground cable.

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

(g) for Automatic transaxle:

(1) Pull up the lever and disconnect the 2 clamps and ECM connector.

(h) for Manual Transaxle:

(1) Pull up the lever, remove the bolt and disconnect the 2 clamps and ECM connector.

(i) Disconnect the 2 clamps, remove the nut and separate the positive (+) cable.

(j) Remove the bolt and separate the ground cable.

29. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Remove the clip and nut, and separate the transmission control cable.

30. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Remove the 4 clips and disconnect the 2 transmission control cables.

31. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the 2 bolts and No. 2 engine mounting stay RH.

32. REMOVE ENGINE MOVING CONTROL ROD

(a) Remove the 4 bolts and engine moving control rod.

33. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Disconnect the No. 1 oil reservoir to pump hose.

34. DISCONNECT RETURN TUBE SUB-ASSEMBLY

(a) Disconnect the return tube sub-assembly.

35. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR

(a) except PZEV:

(1) Disconnect the No. 1 vacuum hose connector.

(b) for PZEV:

(1) Disconnect the 2 No. 1 vacuum hose connectors.

36. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Removal

37. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Removal

38. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Release the claw and remove the No. 1 fuel pipe clamp.

(b) Pinch the fuel tube connector and then pull out the fuel main tube.

NOTICE:
* Check for dirt and foreign objects on the pipe and around the connector. Clean if necessary and then disconnect the connector.
* Disconnect the connector by hand.
* Do not bend, fold or rotate the nylon tube.
* If the pipe and connector are stuck together, push and pull the connector until it becomes free.
* Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

39. DISCONNECT CLUTCH HOSE (for Manual Transaxle)

(a) Disconnect the No. 1 clutch hose and remove the clip.

40. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

41. REMOVE FRONT AXLE HUB NUT LH Removal

42. REMOVE FRONT AXLE HUB NUT RH

HINT
Use the same procedure described for the LH side.

43. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

44. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

45. SEPARATE FRONT SPEED SENSOR LH Removal

46. SEPARATE FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

47. SEPARATE TIE ROD ASSEMBLY LH Removal

48. SEPARATE TIE ROD ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

49. SEPARATE NO. 1 FRONT LOWER SUSPENSION ARM LH Removal

50. SEPARATE NO. 1 FRONT LOWER SUSPENSION ARM RH

HINT
Use the same procedure described for the LH side.

51. SEPARATE FRONT AXLE ASSEMBLY LH Removal

52. SEPARATE FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

53. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

54. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Remove the 2 bolts and No. 1 exhaust pipe support bracket.

55. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the flywheel housing under cover.

56. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)

(a) Using SST, hold the crankshaft pulley.

SST : 09213-54015

SST : 09330-00021

SST : 91551-80650

(b) Remove the 6 drive plate and torque converter clutch setting bolts.

HINT
There will be one black colored bolt.

57. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

NOTICE:
* Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
* Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
* 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 or removed from an engine stand.

(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) Operate the engine lifter, then remove the engine assembly from the vehicle.

NOTICE:
Make sure that the engine is clear of all wiring and hoses.

58. INSTALL ENGINE HANGERS

(a) Install the 2 engine hangers with new 2 bolts as shown in the illustration.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

NOTICE:
Be sure to use new bolts to install the engine hanger.

HINT
Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.

(b) Attach the engine sling device and hang the engine with the chain block.

59. REMOVE ENGINE WIRE

60. REMOVE V-RIBBED BELT (for Vane Pump) Removal

61. REMOVE V-RIBBED BELT (for Compressor and Generator) Removal

62. REMOVE COMPRESSOR AND PULLEY (for TMC Made) Removal

63. REMOVE COMPRESSOR AND PULLEY (except TMC Made) Removal

64. REMOVE GENERATOR ASSEMBLY Removal

65. REMOVE STARTER ASSEMBLY Removal

66. SEPARATE VANE PUMP ASSEMBLY

(a) Remove the 2 bolts and separate the vane pump assembly.

67. REMOVE PUMP BRACKET

(a) Remove the 3 bolts and pump bracket.

68. REMOVE V-RIBBED BELT TENSIONER SUB-ASSEMBLY (for Vane Pump)

(a) Remove the 3 bolts and V-ribbed belt tensioner sub-assembly.

69. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

70. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH (for TMC Made) Disassembly

71. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH (for TMMK Made) Disassembly

72. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

73. REMOVE FRONT FRAME ASSEMBLY

(a) for Manual transaxle:

(1) Loosen the through bolt

(2) Remove the 2 hole plugs.

(3) Remove the 2 nuts and separate the engine lateral control rod.

(b) for Manual transaxle:

(1) Loosen the 3 bolts and 2 nuts.

(d) Remove the 5 hole plugs.

(e) Remove the 9 nuts, and separate the front frame assembly.

74. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the nut and front engine mounting insulator.

75. REMOVE ENGINE MOUNTING INSULATOR LH

(a) for Manual transaxle:

(1) Remove the 3 bolts and engine mounting insulator LH.

(b) for Automatic Transaxle:

(1) Remove the nut and engine mounting insulator LH.

76. REMOVE ENGINE MOUNTING INSULATOR RH

(a) Remove the nut and engine mounting insulator RH.

77. REMOVE ENGINE LATERAL CONTROL ROD (for Manual Transaxle)

(a) Remove the through bolt, nut and engine lateral control rod.

78. REMOVE NO. 2 REAR ENGINE MOUNTING BRACKET (for Manual Transaxle)

(a) Remove the 2 bolts and No. 2 rear engine mounting bracket.

79. REMOVE REAR ENGINE MOUNTING BRACKET (for Manual Transaxle)

(a) Remove the 3 bolts and rear engine mounting bracket.

80. REMOVE DRIVE SHAFT BEARING BRACKET (for Automatic Transaxle)

(a) Remove the 3 bolts and drive shaft bearing bracket.

81. REMOVE ENGINE MOUNTING BRACKET RH

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

82. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

HINT
Removal.

83. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

HINT
Removal.

84. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

HINT
Removal.

85. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) Removal

86. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

87. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Removal

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

89. INSTALL ENGINE STAND

(a) Install the engine onto an engine stand with the bolts.