ENGINE UNIT REMOVAL


  1. INSTALL ENGINE STAND


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

  2. REMOVE ENGINE HANGERS


    1. A003RGQ

      Remove the 2 bolts and 2 engine hangers.

  3. REMOVE THROTTLE BODY ASSEMBLY


    1. A003S9R

      Disconnect the throttle body connector and the 2 water by-pass hoses.

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

    3. A003S6R

      Remove the gasket from the intake manifold.

  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A003UU4

      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


    1. A003SHC

      Disconnect the 2 wire harness clamps.

    2. A003U8S

      Remove the bolt and wire harness support.

    3. A003TVM

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

  6. REMOVE EGR VALVE ASSEMBLY


    1. A003SPT

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

    2. A003TUGE01
      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. A003SJV

      Remove the 2 nuts, EGR valve assembly and gasket.

  7. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY


    1. A003SPT

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

    2. A003TUGE01
      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. A003RQ1

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

  8. REMOVE INTAKE MANIFOLD


    1. A003SBT

      Disconnect the 3 connectors and 2 wire harness clamps.

    2. Remove the engine oil level dipstick.

    3. A003SLW

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

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

    5. A003TLT

      Disconnect the fuel vapor feed hose and ventilation hose.

    6. A003RNA

      Remove the 2 bolts, 2 nuts and intake manifold.

    7. Remove the No. 1 intake manifold to head gasket.

  9. REMOVE FUEL VAPOR FEED PIPE


    1. A003UUQ

      Remove the bolt and fuel vapor feed pipe.

  10. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A003TVP

      Remove the bolt.

    2. A003U2J

      Remove the 2 bolts and the fuel delivery pipe sub-assembly.

      Note

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

  11. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A003U9V

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

  12. REMOVE FUEL INJECTOR ASSEMBLY


    1. A003RM7

      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 to each injector shaft.

      Note

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

    4. A003RIE

      Remove the 4 injector vibration insulators.

  13. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A003RW8

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

  14. REMOVE MANIFOLD STAY


    1. A003UHT

      Remove the 3 bolts and manifold stay.

  15. REMOVE EXHAUST MANIFOLD


    1. A003RGD

      Remove the 7 nuts, exhaust manifold and 2 gaskets.

  16. REMOVE VENTILATION HOSE


    1. A003UTO

      Remove the ventilation hose from the ventilation valve.

  17. REMOVE IGNITION COIL ASSEMBLY


    1. A003SYS

      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.