Click here

ENGINE UNIT REMOVAL

Click here
Click here Click here
Tip:

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

Click here
  1. Click here

    REMOVE V-RIBBED BELT


    1. A01H0QK

      Rotate the tensioner pulley counterclockwise to loosen the V-ribbed belt tension assembly.

      Tip:

      The pulley bolt for the V-ribbed belt tensioner assembly has a left-handed thread.

    2. A01H1D9E01

      While turning the V-ribbed belt tensioner assembly counterclockwise, align the holes. Insert a bar with a diameter of 5 mm (0.197 in.) into the holes to fix the V-ribbed belt tensioner assembly in place.

    3. Remove the V-ribbed belt.

  2. Click here

    REMOVE WITH MOTOR COMPRESSOR ASSEMBLY


    1. A01GZLE

      Disconnect the connector.

    2. Remove the 2 bolts and 2 nuts.

    3. Using an E8 ''TORX'' socket wrench, remove the 2 stud bolts and with motor compressor assembly.

  3. Click here

    REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY


    1. Support the front differential carrier assembly with a jack.

      CAUTION:

      As the front differential carrier assembly is very heavy, securely support it with the jack.

    2. A01H1TL

      Remove the 4 bolts and front differential carrier assembly.

      Note:

      • Do not damage the installation surface when removing the front differential carrier assembly.

      • The remaining oil may leak out when removing the front differential carrier assembly.

  4. Click here

    REMOVE ENGINE COVER SUB-ASSEMBLY LH


    1. A01GZYBE01

      Remove the 4 nuts and engine cover LH.

  5. Click here

    REMOVE NO. 6 COVER SUB-ASSEMBLY


    1. Remove the No. 6 cover.

  6. Click here

    REMOVE ENGINE COVER SUB-ASSEMBLY RH


    1. A01GXYYE01

      Remove the 4 nuts and engine cover RH.

  7. Click here

    REMOVE NO. 5 COVER SUB-ASSEMBLY


    1. Remove the No. 5 cover.

  8. Click here

    REMOVE ENGINE WIRE


    1. Engine LH Side:


      1. A01H1Y9

        Disconnect the camshaft timing control valve connector.

      2. Disconnect the 4 ignition coil connectors.

      3. Disconnect the 2 VVT sensor connectors.

      4. Disconnect the fuel pump connector (for high pressure).

      5. Disconnect the fuel injector connector.

      6. Disconnect the 4 clamps.

    2. Engine Front Side:


      1. A01H0HT

        Disconnect the engine coolant temperature sensor connector.

      2. Disconnect the 2 camshaft timing control motor connectors (for Bank 1).

      3. Disconnect the 2 camshaft timing control motor connectors (for Bank 2).

      4. Disconnect the clamp.

      5. Remove the 3 bolts and disconnect the 3 ground wires.

    3. A01GZMK

      Engine RH Side:


      1. Disconnect the camshaft timing control valve connector.

      2. Disconnect the 4 ignition coil connectors.

      3. Disconnect the 2 VVT sensor connectors.

      4. Disconnect the fuel pump connector (for high pressure).

      5. Disconnect the camshaft position sensor connector.

      6. Disconnect the fuel injector connector.

      7. Disconnect the 4 clamps.

    4. A01H04L

      Engine Rear Side:


      1. Disconnect the engine wire connector.

      2. Disconnect the fuel relief valve connector.

      3. Disconnect the 8 clamps.

      4. Remove the 2 bolts and disconnect the 2 ground wires.

    5. Engine Upper Side:


      1. A01H06YE01

        Disconnect the 8 injector connectors as shown in the illustration.

      2. Disconnect the 2 clamps.

      3. A01GZB4

        Disconnect the purge VSV connector.

      4. Disconnect the intake air control valve actuator connector.

      5. Disconnect the 2 clamps and remove the 2 bolts and 2 clamp brackets.

      6. Remove the 4 nuts and remove the engine wire.

  9. Click here

    REMOVE INJECTOR DRIVER


    1. Remove the 2 bolts, 2 nuts and 2 injector drivers with bracket.

      Note:

      Be careful not to drop or strike the injector driver.

  10. Click here

    REMOVE NO. 1 ENGINE COVER

  11. Click here

    REMOVE PURGE VSV


    1. Disconnect the purge line hose from the intake manifold.

    2. Remove the bolt and purge VSV.

  12. Click here

    REMOVE HEATER WATER PUMP ASSEMBLY


    1. Slide the 2 clamps, and disconnect the 2 hoses from the water inlet housing and water by-pass pipe.

    2. Remove the bolt and heater water pump.

  13. Click here

    REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Slide the clamp, and disconnect the water inlet hose from the front water by-pass joint.

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

  14. Click here

    REMOVE INTAKE MANIFOLD ASSEMBLY


    1. Disconnect the 2 water by-pass hoses and No. 1 ventilation hose as shown in the illustration.

    2. A01H0CL

      Remove the 8 bolts, 2 nuts and intake manifold.

    3. Remove the 2 gaskets from the intake manifold.

  15. Click here

    REMOVE FUEL TUBE SUB-ASSEMBLY


    1. Lift up the retainer to release its lock.

    2. Pinch the tube connector and then pull out the fuel tube.

      Note:

      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.

  16. Click here

    REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY


    1. A01GYCME03

      Disconnect the 2 delivery pipe connectors from the delivery pipe.

    2. A01GYHSE01

      Disconnect the 3 fuel hoses.

    3. A01GXSIE02

      Using SST, remove the 2 fuel pressure pulsation dampers.

      09612-24014 09617-24011
    4. A01GY7X

      Remove the 2 clamp bolts shown in the illustration.

    5. Remove the 2 pulsation dampers, 4 gaskets and No. 1 fuel pipe.

  17. Click here

    REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Disconnect the fuel pump connector.

    2. A01H1CZ

      Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the No. 3 fuel pipe sub-assembly from the fuel pump.

      Note:

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

    3. A01GX74E01

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

    4. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe sub-assembly.

  18. Click here

    REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Tip:

    The removal procedures are the same as for the No. 3 fuel pipe sub-assembly.

  19. Click here

    REMOVE FUEL PUMP ASSEMBLY (for Bank 1)


    1. A01GZM4E01

      Disconnect the fuel pump connector.

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

    3. Disconnect the No. 2 fuel hose from the fuel pump.

  20. Click here

    REMOVE FUEL PUMP ASSEMBLY (for Bank 2)


    1. A01H243E01

      Disconnect the fuel pump connector.

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

    3. Disconnect the No. 1 fuel hose from the fuel pump.

  21. Click here

    REMOVE WATER INLET HOUSING


    1. A01H0SI

      Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the water inlet hose.

    2. Remove the 3 bolts, water inlet housing and gasket.

  22. Click here

    REMOVE FUEL DELIVERY PIPE ASSEMBLY


    1. A01GYCME04

      Disconnect the 2 delivery pipe connectors.

    2. A01H163E01

      Disconnect the 4 wire harness clamps.

    3. A01GX4Z

      Remove the 4 bolts and 2 fuel delivery pipes.

      Note:

      When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.

    4. Remove the 4 delivery pipe spacers and 8 insulators from the cylinder head.

  23. Click here

    REMOVE FUEL INJECTOR ASSEMBLY (for Port Injection)


    1. A01GZDDE03

      Remove the 8 fuel injectors from the fuel delivery pipes.

      Note:

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

    2. A01GXQ2

      Disconnect the connector from the injector.

    3. A01GY81E02

      Remove the O-ring from the fuel injector.

  24. Click here

    REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

  25. Click here

    REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

  26. Click here

    REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH

  27. Click here

    REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A01GW61E06

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

      Table 1. Text in Illustration
      *1 Union Nut Wrench
  28. Click here

    REMOVE FUEL DELIVERY PIPE


    1. A01GWRB

      Disconnect the fuel relief valve connector and No. 3 fuel hose.

    2. A01GZUM

      Disconnect the 4 fuel injector connectors.

    3. A01GZ5W

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

      Note:

      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  29. Click here

    REMOVE NO. 2 FUEL DELIVERY PIPE


    1. A01H0D3

      Disconnect the fuel pressure sensor connector.

    2. A01H22N

      Disconnect the 4 fuel injector connectors.

    3. A01GXFD

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

      Note:

      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the No. 2 fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  30. Click here

    REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)


    1. A01GZJSE02

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

      Note:

      • Do not overtighten the vise.

      • Pull and remove the fuel injector assembly in a straight line to avoid damage to the seal surface of the fuel delivery pipe's O-ring.

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

    2. Remove the nozzle holder clamp from the fuel injector assembly.

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

  31. Click here

    REMOVE FUEL INJECTOR SEAL


    1. A01GY3F

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

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

  32. Click here

    REMOVE SEPARATOR CASE


    1. A01GW82

      Remove the 4 bolts and separator case.

  33. Click here

    REMOVE ENGINE WIRE


    1. Disconnect the 4 connectors and 5 clamps.

    2. Remove the bolt and engine wire.

  34. Click here

    REMOVE KNOCK CONTROL SENSOR


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

  35. Click here

    REMOVE IGNITION COIL ASSEMBLY


    1. Remove the 8 bolts and 8 ignition coils.