ENGINE UNIT REMOVAL


  1. INSTALL ENGINE ON ENGINE STAND


    1. Install the engine onto an engine stand with bolts and nuts.

  2. REMOVE ENGINE HANGERS


    1. A01JB9U

      Remove the 2 bolts and 2 engine hangers.

  3. REMOVE THROTTLE BODY ASSEMBLY


    1. Type A:


      1. A01J9BI

        Disconnect the connector and No. 1 water by-pass hose.

      2. Disconnect the No. 2 water by-pass hose.

      3. Remove the 2 bolts, 2 nuts and throttle body assembly.

      4. A01JCH6

        Remove the gasket from the intake manifold.

    2. Type B:


      1. A01JBHM

        Disconnect the connector and No. 1 water by-pass hose.

      2. Disconnect the No. 2 water by-pass hose.

      3. Remove the 4 bolts and throttle body assembly.

      4. A01J8DW

        Remove the gasket from the intake manifold.

  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01JATJ

      Remove the 2 bolts, clamp and engine oil level dipstick guide.

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

  5. REMOVE EGR PIPE ASSEMBLY (w/ EGR System)


    1. A01J9BB

      Disconnect the 2 wire harness clamps.

    2. A01JALE

      Remove the bolt and wire harness support.

    3. A01JCSG

      Remove the 4 bolts, EGR pipe assembly and 2 gaskets.

  6. REMOVE EGR VALVE ASSEMBLY (w/ EGR System)


    1. A01J9SR

      Disconnect the connector, wire harness clamp and 4 water hoses.

    2. A01JC2YE01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    3. Using an E8 "TORX" wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

    4. Remove the gasket.

    5. A01JAWD

      Remove the 2 nuts, EGR valve assembly and gasket.

  7. REMOVE EGR COOLER SUB-ASSEMBLY (w/ EGR System)


    1. A01J9SR

      Disconnect the connector, wire harness clamp and 4 water hoses.

    2. A01JC2YE01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    3. Using an E8 "TORX" wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

    4. Remove the gasket.

    5. A01JBS8

      Remove the 2 nuts, EGR cooler sub-assembly and gasket.

  8. REMOVE NO. 1 WATER BY-PASS PIPE (w/o EGR System)


    1. A01JDAF

      Disconnect the 2 water hoses from the No. 1 water by-pass pipe.

    2. Remove the 2 bolts, nut and No. 1 water by-pass pipe from the cylinder head sub-assembly.

    3. Using an E8 "TORX" socket wrench, remove the stud bolt from the cylinder head sub-assembly.

  9. REMOVE INTAKE MANIFOLD


    1. w/o EGR System:


      1. A01J9RX

        Disconnect the 2 wire harness clamps from the wire harness support.

      2. A01JCAS

        Remove the bolt and wire harness support from the surge tank cover.

      3. A01J9XS

        Remove the 2 bolts and surge tank cover from the intake manifold.

      4. Remove the gasket from the intake manifold.

    2. A01JB11

      Disconnect the 3 connectors and 2 wire harness clamps.

    3. Remove the engine oil level dipstick.

    4. A01JBZ3

      Disconnect the wire harness clamp, and then remove the 2 bolts and engine oil level dipstick guide sub-assembly.

    5. Remove the O-ring from the engine oil level dipstick guide sub-assembly.

    6. A01JC2G

      Disconnect the fuel vapor feed hose and ventilation hose from the intake manifold.

    7. A01J8SH

      Remove the 2 bolts, 2 nuts and intake manifold.

    8. Remove the No. 1 intake manifold to head gasket from the intake manifold.

    9. w/ Stud Bolt:


      1. A01JC8E

        Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.

        Tech Tips

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

  10. REMOVE FUEL VAPOR FEED PIPE


    1. A01JCTA

      Remove the bolt and fuel vapor feed pipe.

  11. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01JC1X

      Remove the bolt.

    2. A01J9MR

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

      Note

      Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

  12. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A01JCSY

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

  13. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01JBO3

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

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

    3. For reinstallation, attach a tag or label with the corresponding cylinder number to each fuel injector shaft.

      Note

      Protect the fuel injector assemblies by covering them with plastic bags.

    4. A01JC7S

      Remove the 4 injector vibration insulators.

  14. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01JCM4E01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  15. REMOVE MANIFOLD STAY


    1. A01J9M6

      Remove the 3 bolts and manifold stay.

  16. REMOVE EXHAUST MANIFOLD


    1. w/ EGR System:


      1. A01J93S

        Remove the 7 nuts, exhaust manifold and 2 gaskets.

    2. w/o EGR System:


      1. A01JAHW

        Remove the 5 nuts, exhaust manifold and gasket.

  17. REMOVE VENTILATION HOSE


    1. A01JA00

      Remove the ventilation hose from the ventilation valve.

  18. REMOVE IGNITION COIL ASSEMBLY


    1. A01JCLW

      Disconnect the 4 ignition coil connectors.

    2. Remove the 4 bolts and 4 ignition coils.

      Note

      When removing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.