ENGINE UNIT REMOVAL


  1. INSTALL ENGINE STAND


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

  2. REMOVE ENGINE HANGERS


    1. Remove the 2 bolts and No. 1 and No. 2 engine hangers.

  3. REMOVE THROTTLE BODY ASSEMBLY


    1. Type A:


      1. A003WJA

        Disconnect the connector.

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

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

      4. A003WFN

        Remove the gasket from the intake manifold.

    2. Type B:


      1. A003VWS

        Disconnect the connector.

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

      3. Remove the 4 bolts and throttle body assembly.

      4. A003WGA

        Remove the gasket from the intake manifold.

  4. 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.

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


    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.

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


    1. A003WCO

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

    2. A003WD3E01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    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.

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


    1. A003WCO

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

    2. A003WD3E01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    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.

  8. REMOVE WATER BY-PASS PIPE (w/o EGR System)


    1. A003YBG

      Disconnect the 2 water by-pass hoses.

    2. Remove the 2 bolts, nut and water by-pass pipe.

  9. REMOVE INTAKE MANIFOLD


    1. w/o EGR System:


      1. A003WJV

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

      2. A003WQ0

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

      3. A003ZUX

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

      4. Remove the gasket from the intake manifold.

    2. A003ZLL

      Disconnect the 3 connectors and 2 wire harness clamps.

    3. Remove the engine oil level dipstick.

    4. A003XWA

      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. A003VBE

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

    7. A003VFZ

      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. A003Y6A

        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. A003W3O

      Remove the bolt and fuel vapor feed pipe.

  11. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A003VP4

      Remove the bolt.

    2. A003Z7A

      Remove the 2 bolts and 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. A003VR5

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

  13. 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 with the corresponding cylinder number to each fuel injector shaft.

      Note

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

    4. A003YPM

      Remove the 4 injector vibration insulators.

  14. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A003YPLE01
      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. A003ZQD

      Remove the 3 bolts and manifold stay.

  16. REMOVE EXHAUST MANIFOLD


    1. w/ EGR System:


      1. A003WMG

        Remove the 7 nuts, exhaust manifold and 2 gaskets.

    2. w/o EGR System:


      1. A003YA8

        Remove the 5 nuts, exhaust manifold and gasket.

  17. REMOVE VENTILATION HOSE


    1. A003XBI

      Remove the ventilation hose from the ventilation valve.

  18. 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.