2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 1 of 11
Last Modified: 4-12-2007 1.6 A
Service Category: Engine/Hybrid System Section: Engine Mechanical
Model Year: 2008 Model: tC Doc ID: RM000001BC300AX
Title: 2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC)
REMOVAL
1. DISCHARGE FUEL SYSTEM
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE BATTERY
(a) Loosen the 2 nuts and remove the battery clamp.
4. REMOVE BATTERY TRAY
5. REMOVE FRONT WHEEL
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE FRONT FENDER APRON SEAL RH
9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
10. DRAIN ENGINE COOLANT
11. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)
12. DRAIN TRANSAXLE OIL (for Manual Transaxle)
13. DISCONNECT RADIATOR HOSE INLET
14. DISCONNECT RADIATOR HOSE OUTLET
15. DISCONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)
16. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)
17. REMOVE RADIATOR ASSEMBLY
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 2 of 11
18. REMOVE AIR CLEANER ASSEMBLY
(a) Remove the air cleaner cap and element .
(b) Remove the clamp of the engine wire.
(c) Remove the 3 bolts from the air cleaner case.
(d) Disconnect the air cleaner case from the No. 1 air cleaner inlet.
19. REMOVE BATTERY CARRIER
(a) Disconnect the clamp of the engine wire.
(b) Remove the 4 bolts and battery carrier.
20. DISCONNECT FUEL MAIN TUBE
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
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(a) Disconnect the heater water inlet hose from the booster
vacuum tube.
23. DISCONNECT HEATER WATER OUTLET HOSE
(a) Disconnect the heater water outlet hose from the air
conditioner tube.
24. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
25. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
26. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
27. REMOVE FAN AND GENERATOR V BELT
28. REMOVE GENERATOR ASSEMBLY
29. REMOVE COOLER COMPRESSOR ASSEMBLY
HINT:
Disconnect the compressor together with the low-pressure and high-pressure hoses, then secure it to
the vehicle side using rope.
30. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
31. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junction block.
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 4 of 11
(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 and ground cable.
32. REMOVE FRONT EXHAUST PIPE ASSEMBLY
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 5 of 11
33. REMOVE COLUMN HOLE COVER SILENCER SHEET
34. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
35. REMOVE FRONT AXLE HUB NUT
36. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH
38. DISCONNECT FRONT SPEED SENSOR LH
39. DISCONNECT FRONT SPEED SENSOR RH
40. SEPARATE TIE ROD END LH SUB-ASSEMBLY
41. REMOVE TIE ROD END RH SUB-ASSEMBLY
42. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH
43. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER RH
44. REMOVE FRONT AXLE HUB LH SUB-ASSEMBLY
45. REMOVE FRONT AXLE HUB RH SUB-ASSEMBLY
46. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Disconnect the No. 1 pump hose.
(b) Disconnect the return tube.
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 6 of 11
(c) Set the engine lifter.
(d) Remove the 2 bolts, 2 nuts and engine mounting
insulator RH.
(e) Remove the through bolt, nut and engine mounting
insulator LH.
(f) Remove the 8 bolts and front suspension member brace
rear RH and LH.
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 7 of 11
(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 No. 1 and No. 2 engine hangers with the bolts
as shown in the illustration.
Parts No.:
ITEM PART NO.
No. 1 Engine hanger 12281-28010
No. 2 Engine hanger 12282-28010
Bolt 91512-61020
Torque: 38 N·m (387 kgf·cm, 28 ft·lbf)
(j) Attach the sling device and the engine with the chain block.
47. REMOVE VANE PUMP ASSEMBLY
48. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER
MEMBER
(a) Remove the through bolt, nut and engine mounting
insulator FR from the engine mounting bracket FR.
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 8 of 11
(b) Remove the through bolt and 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.
49. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
50. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
51. REMOVE STARTER ASSEMBLY
52. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
53. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle)
54. REMOVE DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle)
(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021
(b) Remove the 8 bolts, rear spacer, drive plate and front
spacer.
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 9 of 11
55. REMOVE MANUAL TRANSAXLE ASSEMBLY
56. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)
57. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)
58. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021
(b) Remove the 8 bolts and flywheel.
59. REMOVE DRIVE SHAFT BEARING BRACKET
(a) Remove the 3 bolts and drive shaft bearing bracket.
60. REMOVE OIL DIPSTICK
61. REMOVE OIL DIPSTICK GUIDE
62. REMOVE MANIFOLD STAY
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 10 of 11
63. REMOVE NO. 2 MANIFOLD STAY
64. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
65. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
66. REMOVE WATER INLET
67. REMOVE THERMOSTAT
68. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts and water by-pass pipe.
(b) Remove the gasket from the cylinder block.
69. REMOVE INTAKE MANIFOLD ASSEMBLY
70. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR
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.
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2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2008 tC) Page 11 of 11
77. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
78. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
79. REPLACE PARTIAL ENGINE ASSEMBLY
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