ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE NO. 1 WATER BY-PASS HOSE


    1. A01VG4B

      Disengage the 3 clamps to separate the No. 1 water by-pass hose from the intake manifold and hose clamp.

    2. Slide the 2 hose clips and remove the No. 1 water by-pass hose from the throttle body with motor assembly and inlet heater water hose A.

  2. REMOVE NO. 2 WATER BY-PASS HOSE


    1. A01VKMK

      Disengage the 2 clamps to separate the No. 2 water by-pass hose from the intake manifold.

    2. Slide the 2 hose clips and remove the No. 2 water by-pass hose from the throttle body with motor assembly and EGR valve assembly.

  3. REMOVE INLET HEATER WATER HOSE A


    1. A01VE1J

      Slide the hose clip and remove the inlet heater water hose A from the cylinder head sub-assembly.

  4. REMOVE NO. 2 WATER BY-PASS HOSE


    1. A01VM6A

      Slide the hose clip and remove the No. 2 water by-pass hose from the cylinder head sub-assembly.

  5. REMOVE AIR CLEANER CAP SUPPORT

    Click here

  6. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  7. REMOVE THROTTLE BODY GASKET

    Click here

  8. REMOVE EFI FUEL PIPE CLAMP

    Click here

  9. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A01VH00E02
      Text in Illustration
      *1 Retainer
      *2 O-ring
      *3 Fuel Tube Connector
      *4 Nylon Tube
      *5 Fuel Pipe
      A01VL3H Pinch
      A01VE7C Pull

      Disengage the clamp to separate the fuel tube sub-assembly from the fuel hose clamp.

    2. Remove the fuel tube sub-assembly from the fuel delivery pipe.


      1. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the nylon tube.

      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

        Note

        Do not damage the fuel tube connector and fuel pipe, and do not allow foreign matter to enter the fuel pipe.

  10. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01VIYU

      Remove the bolt and wire harness clamp bracket from the cylinder head cover sub-assembly.

  11. REMOVE INTAKE MANIFOLD


    1. A01VLKK

      Slide the hose clip and disconnect the No. 2 fuel vapor feed hose from the duty vacuum switching valve.

    2. Remove the 2 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly.

  12. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

    Click here

  13. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    Click here

  14. REMOVE NO. 2 INTAKE MANIFOLD TO HEAD GASKET

    Click here

  15. REMOVE EGR VALVE ASSEMBLY


    1. A01VF56

      Remove the EGR valve assembly from the cylinder head sub-assembly.

  16. REMOVE EGR VALVE GASKET

    Click here

  17. REMOVE MANIFOLD STAY

    Click here

  18. REMOVE EXHAUST MANIFOLD

    Click here

  19. REMOVE EXHAUST MANIFOLD TO HEAD GASKET

    Click here

  20. REMOVE INLET EGR GASKET

    Click here

  21. REMOVE NO. 1 IGNITION COIL

    Click here

  22. REMOVE FUEL DELIVERY PIPE


    1. Make sure that there are no deposits such as sand or grit near the fuel injector assembly, and if there are any deposits, clean them away.

      Note

      Do not allow foreign matter to enter any other components.

    2. A01VEO6E04

      Using a 12 mm union nut wrench, loosen bolt A.

      Tech Tips

      Bolt A interferes with the cylinder head cover sub-assembly and cannot be removed by itself, so remove it together with the fuel delivery pipe.

    3. Remove bolt B.

    4. Remove the fuel delivery pipe with the fuel injector assembly and bolt A from the cylinder head sub-assembly.

      Note


      • Do not allow any foreign matter to enter the cylinder head sub-assembly.

      • Do not drop the fuel injector assemblies when removing the fuel delivery pipe.

  23. REMOVE INJECTOR VIBRATION INSULATOR

    Click here

  24. REMOVE FUEL PIPE INSULATOR

    Click here

  25. REMOVE FUEL INJECTOR ASSEMBLY

    Click here

  26. REMOVE DUTY VACUUM SWITCHING VALVE


    1. A01VH2O

      Remove the bolt and duty vacuum switching valve from the cylinder head cover sub-assembly.

  27. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01VGKC

      Remove the bolt and V-ribbed belt tensioner assembly from the timing chain cover sub-assembly.

  28. REMOVE VENTILATION HOSE


    1. A01VL6G

      Slide the 2 hose clips and remove the ventilation hose from the PCV valve (ventilation valve sub-assembly) and cylinder head cover sub-assembly.

  29. REMOVE NO. 2 VENTILATION HOSE


    1. A01VJFJ

      Slide the hose clip and remove the No. 2 ventilation hose from the cylinder head cover sub-assembly.

  30. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01VG2I

      Remove the bolt and wire harness clamp bracket from the timing chain cover sub-assembly.

    2. A01VIP1

      Remove the bolt and wire harness clamp bracket from the cylinder head cover sub-assembly.