ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE MANIFOLD STAY

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  2. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  3. REMOVE EXHAUST MANIFOLD GASKET

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  4. REMOVE EXHAUST COOLER ASSEMBLY

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  5. REMOVE EXHAUST MANIFOLD TO HEAD GASKET

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  6. REMOVE EGR PIPE GASKET

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  7. REMOVE VENTILATION HOSE ASSEMBLY


    1. A0047M8

      Disengage the clamp to separate the ventilation hose assembly from the hose clamp.

    2. Slide the 3 hose clips and remove the ventilation hose assembly from the cylinder head cover sub-assembly, EGR cooler assembly and intake manifold.

  8. REMOVE EGR VALVE ASSEMBLY


    1. A0049LPC01
      *1 No. 4 Water By-pass Hose
      *2 No. 2 Water By-pass Hose

      Slide the hose clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    2. Slide the hose clip and disconnect the No. 2 water by-pass hose from the EGR valve assembly.

    3. Disengage the clamp to separate the No. 2 water by-pass hose from the hose clamp.

    4. A004B4I

      Remove the 2 bolts, 2 nuts and EGR valve bracket from the EGR valve assembly, EGR cooler assembly, camshaft housing sub-assembly and timing chain cover assembly.

    5. A0046WL

      Remove the bolt, 2 nuts and EGR valve assembly together with the EGR cooler assembly and EGR pipe assembly from the intake manifold and cylinder head sub-assembly.

  9. REMOVE EGR INLET GASKET


    1. A0048QG

      Remove the EGR inlet gasket from the intake manifold.

  10. REMOVE PURGE VALVE (PURGE VSV)


    1. A0049MD

      Disconnect the No. 2 fuel vapor feed hose from the purge valve (purge VSV).

    2. Remove the bolt and purge valve (purge VSV).

  11. REMOVE INTAKE MANIFOLD


    1. A00498C

      Disengage the clamp to separate the No. 4 engine wire connector from the intake manifold.

    2. Slide the hose clip and disconnect the water by-pass hose from the cylinder head sub-assembly.

    3. Remove the 3 bolts, 2 nuts and intake manifold from the cylinder head sub-assembly.

  12. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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  13. REMOVE NO. 6 ENGINE WIRE


    1. A0048EG

      Disconnect the 4 fuel injector assembly connectors.

    2. Disengage the 4 clamps to remove the No. 6 engine wire from the wire harness clamp bracket and cylinder head cover sub-assembly.

  14. REMOVE NO. 2 WATER BY-PASS PIPE


    1. A0046ZX

      Slide the hose clip and disconnect the No. 6 water by-pass hose from the No. 1 water by-pass pipe.

    2. Remove the bolt, nut, wire harness clamp bracket and No. 2 water by-pass pipe from the cylinder head cover sub-assembly.

  15. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A004ABK

      Slide the hose clip and disconnect the No. 1 water by-pass hose from the water inlet with thermostat sub-assembly.

    2. Remove the bolt and No. 1 water by-pass pipe from the cylinder block sub-assembly.

  16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A0046W1

      Remove the 2 bolts and V-ribbed belt tensioner assembly from the timing chain cover assembly.

  17. REMOVE NO. 1 IGNITION COIL

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  18. REMOVE NO. 4 ENGINE WIRE


    1. A00482L

      Disconnect the knock sensor connector to remove the No. 4 engine wire.

  19. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A0048UB

      Remove the 2 bolts and 2 wire harness clamp brackets from the cylinder head cover sub-assembly.

    2. A004ASC

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

    3. A004A2P

      Remove the 2 bolts and 2 wire harness clamp brackets from the timing chain cover assembly.

  20. REMOVE STUD BOLT


    1. A0048YA

      Using an E8 "TORX" socket wrench, remove the stud bolt from the timing chain cover assembly.