ENGINE UNIT REMOVAL


  1. REMOVE GENERATOR ASSEMBLY

    A011BS7

    1. Remove the 2 bolts and the generator.

  2. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    A011ARD

    1. Remove the bolt, 2 nuts and the No. 1 exhaust manifold heat insulator.

  3. REMOVE MANIFOLD STAY

    A011A6U

    1. Remove the bolt, nut and the manifold stay.

  4. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    A011B97

    1. Remove the 3 bolts, 4 nuts and the exhaust manifold converter.

    2. Remove the exhaust manifold to head gasket and inlet EGR gasket from the cylinder head.

  5. DISCONNECT VENTILATION HOSE

    A0119EI

    1. Loosen the clip and disconnect the ventilation hose from the intake manifold.

  6. DISCONNECT NO. 2 WATER BY-PASS HOSE

    A011AUX

    1. Loosen the clip and disconnect the No. 2 water by-pass hose from the throttle body.

  7. DISCONNECT NO. 4 WATER BY-PASS HOSE

    A011BMB

    1. Loosen the clip and disconnect the No. 4 water by-pass hose from the EGR valve.

  8. REMOVE INTAKE MANIFOLD STAY

    A0117HL

    1. Remove the 2 bolts and the intake manifold stay.

  9. REMOVE EGR PIPE CONNECTOR

    A0118NG

    1. Remove the 4 nuts and the EGR pipe connector.

    2. Remove the 2 EGR pipe gaskets from the intake manifold and EGR valve.

  10. REMOVE INTAKE MANIFOLD ASSEMBLY

    A011BRY

    1. Remove the 5 bolts, 2 nuts and the intake manifold.

    2. A011A93

      Remove the intake manifold to head gasket from the cylinder head.

    3. A0117Z0

      Remove the EGR delivery chamber from the cylinder head.

    4. A0117ZA

      Remove the No. 2 intake manifold to head gasket from the cylinder head.

  11. REMOVE NO. 4 ENGINE WIRE

    A011BC9

    1. Disconnect the 2 camshaft timing oil control valve connectors.

    2. Disconnect the 4 ignition coil connectors.

    3. Disconnect the 4 fuel injector connectors.

    4. Remove the ground bolt.

    5. Disengage the 7 clamps and remove the No. 4 engine wire.

  12. REMOVE ENGINE OIL LEVEL DIPSTICK

  13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    A011708

    1. Remove the 2 bolts and the engine oil level dipstick guide.

    2. Remove the O-ring from the oil level dipstick guide.

  14. REMOVE EGR VALVE ASSEMBLY

    A011877

    1. Remove the bolt, 2 nuts and the EGR valve.

    2. Remove the EGR valve gaskets.

  15. REMOVE FUEL DELIVERY PIPE


    1. A011BP1

      Disconnect the 4 fuel injector assembly connectors.

    2. A011889

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

      Note

      Do not drop the fuel injectors when removing the fuel delivery pipe.

  16. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01175T

      Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

    2. A011740

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

      Note

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

  17. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A0117T9

      Remove the 2 No. 1 delivery pipe spacers from the cylinder head.

  18. REMOVE INJECTOR VIBRATION INSULATOR


    1. A0117ZB

      Remove the 4 injector vibration insulators.

  19. REMOVE NO. 1 IGNITION COIL


    1. Remove the 4 bolts and remove the 4 No. 1 ignition coils.

  20. REMOVE VENTILATION HOSE

    A0119L3

    1. Remove the ventilation hose from the cylinder head cover.

  21. REMOVE NO. 2 VENTILATION HOSE

    A011855

    1. Remove the No. 2 ventilation hose from the cylinder head cover.

  22. REMOVE NO. 1 WATER BY-PASS PIPE

    A011A05E01
    Text in Illustration
    *1 No. 2 Water By-Pass Hose
    *2 No. 1 Water By-Pass Pipe
    *3 Water By-Pass Hose

    1. Disengage the No. 2 water by-pass hose from the 3 clamps.

    2. Remove the 3 bolts.

    3. Disconnect the water by-pass hose and remove the No. 1 water by-pass pipe.

  23. REMOVE NO. 2 IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)

    A0119MW

    1. Remove the 4 bolts and the No. 2 idle pulley assembly with bracket.

  24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    A011A92

    1. Remove the 2 bolts and the V-ribbed belt tensioner.

  25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (w/ No. 1 Engine Cover)

    A011A9N

    1. Remove the 2 bolts, V-ribbed belt tensioner and engine cover bracket.

  26. REMOVE WIRING HARNESS CLAMP BRACKET

    A0117UW

    1. Remove the bolt and the wiring harness clamp bracket from the cylinder head cover.

    2. A011AOO

      Remove the bolt and the wiring harness clamp bracket from the cylinder head.

    3. A011AM7

      Remove the bolt and the wiring harness clamp bracket from the cylinder block.