ENGINE UNIT REMOVAL


  1. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B000HBU

      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.

  2. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. B000GXT

      Remove the 4 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  3. REMOVE EGR PIPE CONNECTOR


    1. B000JFS

      Remove the 4 bolts, nut and EGR pipe connector from the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut
    2. B000L15

      Remove the 2 EGR cooler gaskets from the EGR pipe connector.

  4. REMOVE MANIFOLD STAY


    1. B000HXZ

      Remove the bolt, nut and manifold stay from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly.

  5. REMOVE NO. 2 MANIFOLD STAY


    1. B000HYA

      Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly.

  6. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. B000KES

      Remove the 5 nuts and exhaust manifold converter sub-assembly (TWC: Front Catalyst) from the cylinder head sub-assembly.

    2. B000J7F

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

  7. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. B000NEF

      Remove the 4 bolts and No. 1 compressor mounting bracket.

  8. REMOVE FUEL PUMP PROTECTOR


    1. B000MEM

      Remove the 2 bolts and fuel pump protector from the cylinder head cover sub-assembly.

  9. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for Direct Injection)

    Note

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. Disconnect the fuel tube sub-assembly from the No. 1 fuel pipe.


      1. B000MGZE04
        Text in Illustration
        *a Fuel Tube Connector Cover
        B000K70 Pull off

        Pull off the fuel tube connector cover.

      2. B000HHQE01
        Text in Illustration
        *a Retainer
        *b Fuel Tube Connector
        *c Nylon Tube
        *d O-ring
        *e Fuel Pipe
        B000K70 Pinch
        B000IB9 Pull

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      3. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.


        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).


        • Do not bend, twist, pinch or kink the nylon tube.

      4. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  10. REMOVE NO. 1 FUEL PIPE


    1. B000HE3

      Remove the No. 1 fuel pipe and gasket from the fuel pump with seal sub-assembly.

  11. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B000I5W

      Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

    2. B000LKK

      Loosen the 2 bolts of the fuel pump with seal sub- assembly.

    3. Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe sub-assembly and fuel pump with seal sub- assembly.

  12. REMOVE FUEL PUMP WITH SEAL SUB-ASSEMBLY


    1. B000MWH

      Disconnect the fuel pump with seal sub-assembly connector.

    2. Remove the 2 bolts and fuel pump with seal sub- assembly from the cylinder head cover sub- assembly.

    3. B000JICE01
      Text in Illustration
      *1 Fuel Pump with Seal Sub-assembly
      *2 Fuel Pump Insulator
      *3 Fuel Pump Lifter Assembly
      *4 Fuel Pump Lifter Guide

      Remove the fuel pump lifter guide, fuel pump lifter assembly and fuel pump insulator from the fuel pump with seal sub-assembly.

    4. B000J7L

      Remove the O-ring from the fuel pump sub- assembly.

    5. B000N9UE01
      Text in Illustration
      *1 Fuel Pump Spacer Gasket
      *2 O-ring

      Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly.

    6. Remove the 2 O-rings from the No. 4 camshaft bearing cap.

  13. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for Port Injection)

    Note

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. Disconnect the fuel tube sub-assembly from the fuel delivery pipe.


      1. B000MGZE03
        Text in Illustration
        *a Fuel Tube Connector Cover
        B000K70 Pull off

        Pull off the fuel tube connector cover.

      2. B000LMBE01
        Text in Illustration
        *a Retainer
        *b Fuel Tube Connector
        *c Nylon Tube
        *d O-ring
        *e Fuel Pipe
        B000K70 Pinch
        B000IB9 Pull

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      3. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.


        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).


        • Do not bend, twist, pinch or kink the nylon tube.

      4. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  14. REMOVE FUEL DELIVERY PIPE


    1. B000JXY

      Remove the 2 bolts and fuel delivery pipe with the port fuel injector assemblies.

      Note

      Be careful not to drop the port fuel injector assemblies when removing the fuel delivery pipe.

  15. REMOVE FUEL DELIVERY SPACER


    1. B000LWR

      Remove the 2 fuel delivery spacers from the cylinder head sub-assembly.

  16. REMOVE INJECTOR VIBRATION INSULATOR


    1. B000MRT

      Remove the 4 injector vibration insulators from the cylinder head sub-assembly.

  17. REMOVE PORT FUEL INJECTOR ASSEMBLY


    1. B000KYP

      Pull the 4 port fuel injector assemblies out of the fuel delivery pipe.

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

    3. Attach a tag or label with the corresponding cylinder number to each port fuel injector assembly so that they can be installed to their original locations.

      Note

      Cover the port fuel injector assemblies with plastic bags to prevent damage and contamination.

  18. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY


    1. B000NN4

      Disconnect the throttle body with motor assembly connector.

    2. Remove the 4 bolts and throttle body with motor assembly from the intake manifold.

      Note

      If the throttle body with motor assembly has been struck or dropped, replace it.

    3. B000L5AE01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 3 Water By-pass Hose

      Slide the 2 clips and disconnect the No. 2 water by-pass hose and No. 3 water by-pass hose from the throttle body with motor assembly.

  19. REMOVE THROTTLE BODY GASKET


    1. B000MAL

      Remove the throttle body gasket from the intake manifold.

  20. DISCONNECT NO. 2 VENTILATION HOSE


    1. B000N7Z

      Slide the clip and disconnect the No. 2 ventilation hose from the PCV valve (ventilation valve sub-assembly).

  21. REMOVE NO. 2 EGR PIPE


    1. B000M5N

      Disengage the 2 wire harness clamps from the No. 2 EGR pipe.

    2. B000MGH

      Remove the 4 bolts and No. 2 EGR pipe from the EGR valve assembly and intake manifold.

    3. B000HBI

      Remove the No. 2 EGR pipe gasket from the EGR valve assembly.

    4. B000KK2

      Remove the EGR inlet gasket from the intake manifold.

  22. REMOVE INTAKE MANIFOLD


    1. B000JU3

      Remove the 6 bolts and intake manifold from the cylinder head sub-assembly.

    2. B000ME8

      Remove the manifold gasket from the intake manifold.

  23. REMOVE NO. 5 ENGINE WIRE


    1. B000KLZ

      Remove the 2 bolts and disconnect the No. 5 engine wire from the fuel delivery pipe sub-assembly.

    2. Disconnect the fuel pressure sensor connector, knock control sensor connector and 4 fuel injector set connectors.

    3. Disengage the 2 clamps and remove the No. 5 engine wire.

  24. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B000JBS

      Remove the 3 bolts, 2 nuts and fuel delivery pipe sub-assembly with the direct fuel injector assemblies.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut

      Note


      • Make sure not to touch or strike the tips of the direct fuel injector assemblies.


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

  25. REMOVE DIRECT FUEL INJECTOR ASSEMBLY


    1. B000LF3E01

      Secure the fuel delivery pipe sub-assembly in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

      Note


      • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe sub-assembly O-ring.


      • Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.

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

    3. Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.

    4. Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.

    5. Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.

  26. REMOVE FUEL INJECTOR SEAL


    1. B000L5W

      Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

      Note


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


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

    2. Remove the fuel injector seal from each direct fuel injector assembly.

  27. REMOVE EGR VALVE WITH COOLER ASSEMBLY


    1. B000HLO

      Disconnect the EGR valve assembly connector.

    2. B000IE5

      Remove the engine cover joint and separate the fuel hose bracket from the EGR valve bracket.

    3. B000JNF

      Remove the 4 bolts and 2 EGR valve brackets.

    4. B000I48

      Disengage the water hose from the hose clamp.

    5. B000HQE

      Slide the clip and disconnect the water hose sub-assembly from the EGR cooler assembly.

    6. B000I5ME01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 3 Water By-pass Hose
      *3 No. 4 Water By-pass Hose

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

    7. Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.

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

    9. B000NPA

      Remove the 2 nuts and EGR valve with cooler assembly from cylinder head sub-assembly.

    10. B000H11

      Remove the No. 2 EGR pipe gasket from the EGR valve assembly.

  28. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B000N8Q

      Remove the dust cover from the V-ribbed belt tensioner assembly.

    2. B000HJ5

      Remove the bolt and V-ribbed belt tensioner assembly from the water inlet housing.

  29. REMOVE NO. 1 WATER BY-PASS PIPE


    1. B000NM9

      Remove the bolt, 2 nuts and No. 1 water by-pass pipe and gasket.

      Text in Illustration
      B000K70 Nut
      B000IB9 Bolt

  30. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B000KRL

      Remove the 7 bolts, engine water pump assembly and water pump gasket.

  31. REMOVE WATER INLET


    1. B000LG5

      Remove the 2 nuts and water inlet.

  32. REMOVE THERMOSTAT


    1. Remove the thermostat from the water inlet housing.

    2. Remove the gasket from the thermostat.

  33. REMOVE OIL COOLER ASSEMBLY


    1. B000HFCE07
      Text in Illustration
      *1 Oil Cooler Union Bolt
      *2 Seal Washer

      Remove the oil cooler union bolt and seal washer.

    2. Remove the nut and oil cooler assembly from the water inlet housing.

    3. Remove the 3 gaskets from the oil cooler assembly.

  34. REMOVE ENGINE OIL TEMPERATURE SENSOR


    1. B000H1W

      Disconnect the engine oil temperature sensor connector.

    2. B000HWJE01
      Text in Illustration
      *1 Engine Oil Temperature Sensor
      *2 Gasket

      Using SST, remove the engine oil temperature sensor from the water inlet housing sub-assembly.

      SST
      09817-33191

      Note

      If the engine oil temperature sensor has been struck or dropped, replace it.

    3. Remove the gasket from the engine oil temperature sensor.

  35. REMOVE WATER INLET HOUSING


    1. B000L5D

      Remove the 4 bolts, nut, water inlet housing and gasket.

      B000K70 Bolt
      B000IB9 Nut

      Note

      If a stud bolt is deformed or its threads are damaged, replace it.

  36. REMOVE IGNITION COIL ASSEMBLY


    1. B000JPZ

      Disconnect the 4 ignition coil assembly connectors.

    2. Remove the 4 bolts and 4 ignition coil assemblies from the cylinder head cover sub-assembly.

      Note

      If an ignition coil assembly has been struck or dropped, replace it.

      Tech Tips

      Arrange the removed parts in the correct order.

  37. REMOVE BRACKET


    1. B000HJ1

      Remove the bolt and bracket from the cylinder head cover sub-assembly.