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ENGINE UNIT REMOVAL

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  1. Click here

    INSTALL ENGINE STAND


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

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    REMOVE ENGINE HANGERS


    1. A003X6R

      Remove the 2 bolts and 2 engine hangers.

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    REMOVE THROTTLE BODY ASSEMBLY


    1. A003WJA

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

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

    3. A003WFN

      Remove the gasket from the intake manifold.

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    REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A003ZA1

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

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

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    REMOVE EGR PIPE ASSEMBLY


    1. A003XYD

      Disconnect the 2 wire harness clamps.

    2. A003YI1

      Remove the bolt and wire harness support.

    3. A003YX6

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

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    REMOVE EGR VALVE ASSEMBLY


    1. A003WCO

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

    2. A003WD3E01

      Remove the 4 nuts and bolt.

      Table 1. Text in Illustration
      *1 Stud Bolt and Nut

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

    4. Remove the gasket.

    5. A003ZIH

      Remove the 2 nuts, EGR valve assembly and gasket.

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    REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY


    1. A003WCO

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

    2. A003WD3E01

      Remove the 4 nuts and bolt.

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

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

    4. Remove the gasket.

    5. A003XRK

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

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    REMOVE INTAKE MANIFOLD


    1. A003ZLL

      Disconnect the 3 connectors and 2 wire harness clamps.

    2. Remove the engine oil level dipstick.

    3. A003XWA

      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. A003VBE

      Disconnect the fuel vapor feed hose and ventilation hose.

    6. A003VFZ

      Remove the 2 bolts, 2 nuts and intake manifold.

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

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    REMOVE FUEL VAPOR FEED PIPE


    1. A003W3O

      Remove the bolt and fuel vapor feed pipe.

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    REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A003VP4

      Remove the bolt.

    2. A003Z7A

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

      Note:

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

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    REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A003VR5

      Remove the 2 delivery pipe spacers from the cylinder head.

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    REMOVE FUEL INJECTOR ASSEMBLY


    1. A003WXD

      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 matter by covering the fuel injectors with plastic bags.

    4. A003YPM

      Remove the 4 injector vibration insulators.

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    REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A003WH1

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

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    REMOVE MANIFOLD STAY


    1. A003ZQD

      Remove the 3 bolts and manifold stay.

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    REMOVE EXHAUST MANIFOLD


    1. A003WMG

      Remove the 7 nuts, exhaust manifold and 2 gaskets.

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    REMOVE VENTILATION HOSE


    1. A003XBI

      Remove the ventilation hose from the ventilation valve.

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    REMOVE IGNITION COIL ASSEMBLY


    1. A003VYT

      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.