ENGINE UNIT REMOVAL


  1. REMOVE ENGINE HANGERS


    1. A01G74SE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No .2 Engine Hanger

      Remove the 2 bolts, No. 1 engine hanger and No .2 engine hanger.

  2. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01G4WS

      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. A01G4J1

      Remove the bolt, nut and manifold stay.

  4. REMOVE NO. 2 MANIFOLD STAY


    1. A01G59Z

      Remove the bolt, nut and No. 2 manifold stay.

  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01G4OI

      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. A01G7NZ

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

    2. A01G80EE01

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

  7. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01G5LU

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

  8. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01G71O

      Disconnect the fuel tube from the fuel tube bracket.

    2. Disconnect the throttle with motor body assembly connector.

    3. A01G9OC

      Disconnect the No. 1 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. A01G825

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

    6. A01G722

      Remove the bolt and fuel tube bracket.

    7. A01G6CY

      Remove the gasket from the intake manifold.

  9. REMOVE WATER BY-PASS HOSE


    1. A01G6E8

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

  10. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. for LHD:


      1. A01G9RQ

        Disconnect the union to vacuum tube hose.

      2. Disengage the wire harness clamp.

    2. for RHD:


      1. Disconnect the union to check valve hose.

      2. Disengage the wire harness clamp.

    3. Disconnect the 2 vacuum hoses and vacuum switching valve assembly connector.

    4. Remove the bolt and vacuum switching valve assembly from the intake manifold.

  11. DISCONNECT NO. 2 VENTILATION HOSE


    1. A01G6SM

      Slide the clip and disconnect the No. 2 ventilation hose from the intake manifold.

  12. DISCONNECT UNION TO VACUUM TUBE HOSE (for LHD)


    1. A01G97A

      Slide the clip and disconnect the union to vacuum tube hose from the intake manifold.

  13. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. A01G97A

      Slide the clip and disconnect the union to check valve hose from the intake manifold.

  14. REMOVE FUEL DELIVERY PIPE


    1. A01G8C7

      Remove the 2 bolts and fuel delivery pipe with the 4 fuel injector assemblies.

      Note

      Do not drop the fuel injector assemblies when removing the fuel delivery pipe.

    2. A01G960E01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *2 Injector Vibration Insulator

      Remove the 2 fuel delivery spacers from the cylinder head.

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

  15. REMOVE INTAKE MANIFOLD


    1. A01G73S

      Remove the 2 bolts and 2 wire harness clamp brackets from the intake manifold.

    2. A01G4TD

      Slide the clip and disconnect the fuel vapor feed hose from the intake manifold.

    3. Disengage the 3 wire harness clamps.

    4. Disconnect the wire harness connector.

    5. Remove the bolt and wire harness clamp bracket.

    6. A01G5MYE01

      Apply battery voltage to the terminals of the connector to close the tumble control valves (w/ TCV).

      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 intake air control valve actuator may be damaged.

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

    7. A01G8Z3E01
      Text in Illustration
      *A w/ TCV
      *B w/o TCV

      Remove the bolt and separate the wire harness.

    8. Disengage the 2 wire harness clamps and disconnect the intake air control valve actuator connector (w/ TCV).

    9. Disengage the 2 wire harness clamps (w/o TCV).

    10. A01G8IH

      Remove the 6 bolts and intake manifold (w/ TCV).

      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 intake air control valve actuator to operate the motor and close the tumble control valves Click here.

    11. A01G81V

      Remove the 6 bolts and intake manifold (w/o TCV).

    12. A01G63C

      Remove the intake manifold gasket from the intake manifold (w/ TCV).

    13. A01G4DR

      Remove the intake manifold gasket from the intake manifold (w/o TCV).

    14. A01G7TV

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

    15. A01G5J4E01

      Remove the bolt and wire harness clamp bracket from the intake manifold.

  16. REMOVE SENSOR WIRE


    1. A01G8PK

      Disconnect the knock control sensor connector.

    2. Remove the bolt and sensor wire.

  17. REMOVE KNOCK CONTROL SENSOR


    1. A01G8X3

      Disconnect the knock control sensor connector.

    2. Remove the bolt and knock control sensor.

  18. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01G4GC

      Disconnect the connector.

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

  19. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01G59K

      Disconnect the engine coolant temperature sensor connector.

    2. A01G88C

      Remove the 2 bolts and disconnect the wire harness.

    3. A01G7ITE01
      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. A01G6KB

      Remove the 4 bolts and 4 ignition coil assemblies.