ENGINE UNIT REMOVAL


  1. INSTALL ENGINE ON ENGINE STAND


    1. Install the engine onto an engine stand with the bolts.

  2. REMOVE ENGINE HANGER


    1. Remove the 2 bolts and 2 engine hangers.

  3. REMOVE ENGINE WIRE


    1. Remove the engine wire.

  4. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A0163GR

      Remove the 4 bolts and front No. 1 engine mounting bracket RH.

  5. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01638P

      Remove the 4 bolts and front No. 1 engine mounting bracket LH.

  6. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A0162HQE01

      Remove the 2 bolts and 2 wire harness clamp brackets.

  7. REMOVE TRANSMISSION BREATHER ASSEMBLY


    1. A015ZQZ

      Remove the bolt and disconnect the ground wire.

    2. Separate the 2 clamps and the wire harness from the transmission breather assembly.

    3. Remove the 2 bolts and the transmission breather assembly.

  8. REMOVE THROTTLE BODY ASSEMBLY


    1. A0162PC

      Disconnect the throttle body assembly connector.

    2. A0162ZZ

      Loosen the hose clamp and separate the No. 5 water by-pass hose.

    3. A0162X5

      Loosen the hose clamp and separate the No. 4 water by-pass hose.

    4. A01628P

      Remove the 2 bolts and 2 nuts.

    5. A01631Y

      Using a "TORX" socket E6, remove the 2 stud bolts and throttle body assembly.

      Note

      Do not damage the water hoses when removing the throttle body assembly.

    6. Remove the gasket.

    7. A0161EH

      Remove the 2 water by-pass hoses from the throttle body assembly.

  9. REMOVE INJECTOR DRIVER


    1. A01606BE01

      Disconnect the 4 injector driver connectors.

      Tech Tips

      To disconnect the injector driver connectors, push the claw downward and move the lock lever to release the lock.

    2. Remove the 8 nuts and 2 injector drivers.

    3. Remove the bolt and No. 2 V-bank cover bracket sub-assembly.

  10. DISCONNECT WATER BY-PASS HOSE


    1. A0162EQ

      Slide the 3 clamps, and disconnect the water by-pass pipe hose, No. 3 water by-pass hose and No. 9 water by-pass hose from the water by-pass pipe sub-assembly.

  11. DISCONNECT VENTILATION HOSE


    1. A0163KF

      Disconnect the ventilation hose from the intake air surge tank sub assembly.

  12. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. A0162R3

      Remove the 8 bolts, 2 nuts and intake air surge tank assembly.

    2. Remove the 2 gaskets from the intake air surge tank assembly.

    3. A0162BF

      Remove the bolt and V-bank cover bracket sub-assembly.

    4. Remove the bolt and union to check valve hose bracket (for LHD).

  13. REMOVE NO. 3 COVER SUB-ASSEMBLY


    1. A01632B

      Remove the bolt and separate the engine wire.

    2. Remove the 2 bolts and bracket.

    3. A0160DB

      Remove the 2 clips and No. 3 cover sub-assembly.

  14. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (for Direct Injection)


    1. A0162WFE01

      Disconnect the harness clamp and remove the 2 bolts and brackets.

    2. A0161PH

      Disconnect the 3 fuel hoses.

    3. A01615AE01

      Using SST, loosen the 2 fuel pressure pulsation damper assemblies.

      SST
      09612-24014   ( 09617-24011 )
    4. A016371

      Remove the 2 clamp bolts shown in the illustration.

    5. A015Z84

      Remove the 4 gaskets and No. 1 fuel pipe sub-assembly.

  15. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Remove the high pressure side fuel pump assembly connector.

    2. A0162CY

      Secure the union bolt on the fuel pump assembly side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the fuel pipe from the fuel pump assembly.

      Note

      Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump assembly.

    3. A016187

      Remove the 2 bolts on the delivery pipe side and remove the No. 3 fuel pipe sub-assembly.

  16. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Remove the high pressure side fuel pump assembly connector.

    2. Secure the union bolt on the fuel pump assembly side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the fuel pipe from the fuel pump assembly.

      Note

      Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump assembly.

      Tech Tips

      Use the same procedure as for the bank 1 side.

    3. A0162DD

      Remove the 2 bolts on the delivery pipe side and separate the No. 2 fuel pipe sub-assembly.

    4. A0160ME

      Remove the bolt and No. 2 fuel pipe sub-assembly.

  17. REMOVE ENGINE COVER SUB-ASSEMBLY (for Bank 1)

    A0163K0E02

    1. Detach the 5 claws and remove the engine cover sub-assembly LH and RH from the fuel pump assembly.

  18. REMOVE ENGINE COVER SUB-ASSEMBLY (for Bank 2)

    Tech Tips

    Use the same procedure as for the bank 1 side.

  19. REMOVE FUEL PUMP ASSEMBLY (for Bank 1)


    1. A0160MK

      Disconnect the fuel hose from the fuel pump assembly.

    2. A01609Z

      Remove the 2 nuts, fuel pump assembly and fuel pump insulator.

  20. REMOVE FUEL PUMP ASSEMBLY (for Bank 2)

    Tech Tips

    Use the same procedure as for the bank 1 side.

  21. REMOVE FUEL PUMP SPACER


    1. Remove the 2 fuel pimp spacers.

  22. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A0160E4

      Remove the No. 1 engine cover sub-assembly.

  23. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH


    1. A0163KT

      Remove the No. 2 engine cover sub-assembly LH.

  24. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A015ZCWE03

      Using a 19 mm union nut wrench, remove the No. 4 fuel pipe sub-assembly.

  25. REMOVE SEPARATOR CASE


    1. A0161F0E03

      Disconnect the fuel pressure sensor connector.

    2. A015Z2V

      Remove the 4 bolts and separator case from the cylinder head.

  26. REMOVE NO. 2 FUEL DELIVERY PIPE (for Direct Injection)


    1. A0162M6

      Disconnect the 4 injector connectors.

    2. A0162DC

      Remove the 5 bolts and the No. 2 fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull the No. 2 fuel delivery pipe straight without tilting it.

    3. A0161WA

      Remove the 4 injector vibration insulators from the cylinder head.

  27. REMOVE FUEL DELIVERY PIPE (for Direct Injection)


    1. A0162VZ

      Disconnect the 4 injector connectors.

    2. A0161AR

      Remove the 5 bolts and the fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull the fuel delivery pipe straight without tilting it.

    3. A015ZX7

      Remove the 4 injector vibration insulators from the cylinder head.

  28. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)


    1. A0163BJE01

      Secure the delivery pipe between aluminum plates in a vise and pull the fuel injector assembly out in a straight line.

      Note


      • Pull the fuel injector assembly straight out to avoid damage to the seal surface of the fuel delivery pipe and No.2 fuel delivery pipe O-ring.

      • For reinstallation, attach a tag or label to the injector shaft.

    2. A01601T

      Remove the nozzle holder clamp from the injector assembly.

    3. Remove the O-ring, backup rings (No. 1, No. 2 and No. 3) and E-ring from the fuel injector.

  29. REMOVE FUEL INJECTOR SEAL (for Direct Injection)


    1. A0161WC

      Using the tips of needle-nose pliers, pinch and pull one of the 2 fuel injector seals at several points to stretch it. Repeat this for the other fuel injector seal.

      Note


      • Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.

      • If an fuel injector assembly is dropped or the tip of an fuel injector assembly is struck, replace it with a new one.

    2. Remove the 2 fuel injector seals from the fuel injector assembly.

  30. REMOVE NO. 5 ENGINE WIRE


    1. A0160DJ

      Disconnect the 4 knock sensor connectors.

    2. Remove the 2 bolts and No. 5 engine wire.

  31. REMOVE NO. 4 ENGINE COVER SUB-ASSEMBLY


    1. A0161BC

      Remove the engine cover.

  32. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A0161UQ

      Remove the bolt and idler pulley sub-assembly.

  33. REMOVE OIL PUMP DRIVE SHAFT PULLEY


    1. A016325E01

      Using SST, hold the oil pump drive shaft pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )

    2. Remove the 4 bolts and oil pump drive shaft pulley.

  34. REMOVE WATER PUMP PULLEY


    1. A0160QTE01

      Using a screwdriver or an equivalent, hold the water pump pulley.

      Tech Tips

      Tape the screwdriver tip before use to avoid damage.

    2. Remove the 4 bolts and water pump pulley.

  35. REMOVE INLET WATER HOUSING


    1. A0162AF

      Remove the hose clamp and disconnect the water inlet hose.

    2. A0162EY

      Remove the 3 bolts, inlet water housing and gasket.

  36. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A0160OL

      Using a deep socket wrench (24 mm) remove the engine oil pressure switch assembly.

  37. REMOVE OIL TEMPERATURE SENSOR


    1. Disconnect the temperature sensor connector.

    2. A0163J8E02

      Using SST, remove the temperature sensor and gasket.

      SST
      09922-10010

      Note


      • Do not subject the oil temperature sensor to any impacts.

      • If the sensor is subjected to an impact, replace the oil temperature sensor with a new one.

  38. REMOVE ENGINE OIL LEVEL SENSOR


    1. A0162T1

      Disconnect the engine oil level sensor connector.

    2. Remove the 4 bolts.

    3. A015ZZD

      Rotate the engine oil level sensor 180° counterclockwise and remove it.

    4. A015Z0EE02

      Cut off the gasket as shown in the illustration.

    5. Remove the gasket from the oil level sensor.

      Tech Tips

      After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

  39. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A0162JT

      Remove the 3 hose clamps and disconnect the 3 water by-pass hoses.

    2. Remove the 4 bolts and No. 2 water by-pass pipe sub-assembly.

  40. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR


    1. A015YGYE01

      Disconnect the E.F.I. engine coolant temperature sensor connector.

    2. Remove the E.F.I. engine coolant temperature sensor.

    3. Remove the gasket from the E.F.I engine coolant temperature sensor.

  41. REMOVE KNOCK SENSOR

    A015YQFE01

    1. Disconnect the 4 knock control sensor connectors.

    2. Remove the 4 bolts and 4 knock control sensors.

  42. REMOVE IGNITION COIL ASSEMBLY


    1. Disconnect the 8 ignition coil connectors.

    2. A0160Z7E01

      Remove the 8 bolts and 8 ignition coil assemblies.

      Note

      Do not damage the ignition coil assemblies when removing them.

  43. REMOVE NO. 4 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. A01635G

      Remove the nut and No. 4 V-bank cover bracket.

  44. REMOVE NO. 3 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. A0163F5

      Remove the bolt and No. 3 V-bank cover bracket.