ENGINE UNIT REMOVAL


  1. REMOVE ENGINE HANGERS


    1. A01HYISE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No .2 Engine Hanger

      Remove the 2 bolts and 2 engine hangers.

  2. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01HXO8

      Remove the engine oil level dipstick.

    2. Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  3. REMOVE MANIFOLD STAY


    1. A01HY3K

      Remove the bolt, nut and manifold stay from the exhaust manifold converter sub-assembly and stiffening crankcase assembly.

  4. REMOVE NO. 2 MANIFOLD STAY


    1. A01I10Z

      Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold converter sub-assembly and stiffening crankcase assembly.

  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01I0MS

      Remove the 4 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly.

  6. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01I1IU

      Remove the 5 nuts and exhaust manifold converter sub-assembly from the cylinder head sub-assembly.

    2. A01HYLLE01

      Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

  7. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01I277

      Remove the 4 bolts and bracket.

  8. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01I23I

      Disconnect the fuel tube from the clamp.

    2. Disconnect the throttle body connector.

    3. A01I01R

      Disconnect the water by-pass hose from the throttle with motor body assembly.

    4. Disconnect the No. 2 water by-pass hose from the throttle with motor body assembly.

    5. A01I0NW

      Remove the 4 bolts and throttle with motor body assembly with fuel tube bracket.

    6. A01HY83

      Remove the bolt and fuel tube bracket.

    7. A01HZI8

      Remove the gasket from the intake manifold.

  9. REMOVE WATER BY-PASS HOSE


    1. A01I0K2

      Remove the No. 1 and No. 2 water by-pass hoses.

  10. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. A01HXV7

      Disconnect the union to connector tube hose and wire harness clamp.

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  11. DISCONNECT NO. 2 VENTILATION HOSE


    1. A01HZWS

      Disconnect the No. 2 ventilation hose from the intake manifold.

  12. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A01HZX2

      Disconnect the union to connector tube hose from the intake manifold.

  13. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01HXOG

      Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors.

      Note

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

    2. A01I1AV

      Remove the 2 fuel delivery spacers from the cylinder head.

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

  14. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01I0ANE01

      Pull the 4 fuel injectors out of the fuel delivery pipe.

    2. Remove the O-ring from each fuel injector.

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

      Note

      Prevent entry of foreign matter by covering the fuel injectors with plastic bags.

  15. REMOVE INTAKE MANIFOLD


    1. A01HYLI

      Remove the 2 bolts and 2 wire harness clamp brackets.

    2. A01HXIE

      Disconnect the fuel vapor feed hose.

    3. Disconnect the 3 wire harness clamps and connector.

    4. Remove the bolt and wire harness clamp bracket.

    5. A01I25U

      Apply battery voltage to the terminals of the connector to close the tumble control valves.

      Standard
      Tester Connection Specified Condition
      Positive (+) battery voltage applied to terminal 8 (M-), and negative (-) battery voltage applied to terminal 4 (M+) Open → Closed

      Note


      • If this procedure is not performed, the tumble control valves may be damaged when the intake manifold is removed.

      • Apply battery voltage for 1 to 3 seconds.

      • If battery voltage is applied for more than 3 seconds, the actuator may be damaged.

      • Do not allow the lead wires to contact the other terminals.

    6. A01HZMV

      Remove the bolt and separate the wire harness.

    7. Disconnect the 2 wire harness clamps and intake air control valve actuator connector.

    8. A01HZOZ

      Remove the 6 bolts and intake manifold.

      Note

      The tumble control valves may be damaged if they are not closed before removing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the actuator to operate the motor and close the valves Click here.

    9. A01HYFJ

      Remove the intake manifold gasket from the intake manifold.

    10. A01HXI4

      Disconnect the 2 vacuum hoses from the intake manifold and remove the No. 1 check valve.

    11. A01I0Q1

      Remove the bolt and wire harness clamp bracket.

  16. REMOVE SENSOR WIRE


    1. A01HYML

      Disconnect the knock control sensor connector.

    2. Remove the bolt and knock control sensor wire.

  17. REMOVE KNOCK CONTROL SENSOR


    1. A01HZAN

      Disconnect the sensor connector.

    2. Remove the bolt and knock control sensor.

  18. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01I0YU

      Disconnect the connector.

    2. Using a 24 mm deep socket wrench, remove the oil pressure switch.

  19. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01I083

      Disconnect the engine coolant temperature sensor connector.

    2. A01I281

      Remove the 2 bolts and disconnect the wire harness.

    3. A01I07IE01
      Text in Illustration
      *1 Ball Joint Lock Nut Wrench
      *2 Gasket

      Using a 19 mm ball joint lock nut wrench, remove the engine coolant temperature sensor.

    4. Remove the gasket from the engine coolant temperature sensor.

  20. REMOVE IGNITION COIL ASSEMBLY


    1. Disconnect the 4 ignition coil assembly connectors.

    2. A01HXEV

      Remove the 4 bolts and 4 ignition coil assemblies.