ENGINE UNIT REMOVAL


  1. REMOVE ENGINE WIRE

  2. DISCONNECT HEATER WATER HOSE ASSEMBLY


    1. A01DUW9E01
      Text in Illustration
      *A w/o Warmer
      *B w/ Warmer

      w/o Warmer:

      Disconnect the 2 hoses and remove the heater water hose assembly.

    2. w/ Warmer:

      Disconnect the 3 hoses and remove the heater water hose assembly.

  3. REMOVE EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. A01DRM3

      Remove the 3 nuts and emission control valve set.

  4. REMOVE NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. A01DRXW

      Remove the 3 nuts and No. 2 emission control valve set.

  5. REMOVE IGNITION COIL ASSEMBLY


    1. A01DSL9

      Remove the 6 bolts and 6 ignition coils.

  6. REMOVE REAR CYLINDER HEAD COVER


    1. A01DU8P

      Remove the 3 bolts and cover.

  7. REMOVE FUEL PIPE SUB-ASSEMBLY


    1. A01DPVY

      Disconnect the 2 fuel pipes Click here.

    2. Remove the 2 bolts and No. 1 fuel pipe and No. 2 fuel pipe.

  8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01DOM4

      Disconnect the 6 fuel injector connectors.

    2. Remove the 4 bolts and fuel delivery pipe together with the 6 fuel injectors.

      Note

      Be careful not to drop the injectors when removing the fuel delivery pipe.

  9. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01DT2CE01
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 Fuel Injector

      Remove the 6 fuel injectors from the fuel delivery pipe.

    2. Remove the O-ring and injector vibration insulator from each fuel injector.

  10. REMOVE INTAKE MANIFOLD


    1. A01DRIX

      Remove the 4 nuts, 6 bolts and 2 gaskets.

  11. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)


    1. A01DRXL

      Disconnect the 2 hoses.

    2. Remove the 3 bolts and water by-pass pipe.

  12. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01DRER

      Remove the bolt and No. 1 idler pulley.

  13. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01DPUM

      for Cover Separate Type:

      Remove the 2 bolts, 2 idler pulley cover plates, 2 No. 2 idler pulleys and 2 No. 2 idler pulley cover plates.

    2. for Cover Integrated Type:

      Remove the 2 bolts and 2 No. 2 idler pulleys.

  14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DOD6

      Remove the 5 bolts and V-ribbed belt tensioner.

  15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01DQMN

      Remove the dipstick.

    2. Remove the bolt and dipstick guide.

    3. Remove the O-ring from the dipstick guide.

  16. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01DQ3V

      Remove the 3 bolts and front No. 1 engine mounting bracket LH.

  17. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A01DRWT

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

  18. REMOVE FLYWHEEL RING GEAR (for Manual Transmission)

    Tech Tips

    If the flywheel ring gear is deformed or the gears are damaged, replace it.

    CAUTION:

    Wear protective gloves. Hot areas on the flywheel ring gear may injure your hands.


    1. A01DPDUE01

      Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

    2. Temporarily install 6 bolts (8 mm (0.315 in.) x 1.25 pitch) with a length of 70 mm (2.76 in.) or more to the flywheel.

    3. Uniformly tighten the 6 bolts in the order shown in the illustration.

    4. Remove the ring gear from the flywheel.