ENGINE UNIT REMOVAL


  1. REMOVE FAN AND GENERATOR V BELT


    1. A01FIUU

      While releasing the belt tension by turning the belt tensioner counterclockwise, remove the V belt from the belt tensioner.

    2. A01FHWGE01

      While turning the belt tensioner counterclockwise, align its holes, and then insert the 5 mm bi-hexagon wrench into the holes to secure the belt tensioner.

  2. REMOVE NO. 2 ENGINE COVER


    1. A01FH26

      Remove the 3 clips and clamp, then remove the No. 2 engine cover.

  3. REMOVE NO. 1 ENGINE COVER


    1. A01FIZP

      Remove the 3 clips, then remove the No. 1 engine cover.

  4. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01FFAA

      Remove the bolt, No. 2 idler pulley cover plate and No. 2 idler pulley sub-assembly.

  5. REMOVE GENERATOR ASSEMBLY


    1. Remove the terminal cap.

    2. A01FDTZE02

      Remove the nut and disconnect the generator wire.

    3. Disconnect the generator connector, and detach the 2 clamps.

    4. A01FHT9E01

      Disconnect the connector from the cooling fan ECU.

    5. A01FF4B

      Remove the nut, and disconnect the bracket.

    6. A01FDGW

      Remove the 2 bolts and generator.

    7. A01FG6M

      Remove the 2 bolts and 2 brackets.

  6. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. Disconnect the connector.

    2. A01FE74

      Remove the 3 bolts and nut.

    3. A01FHU3

      Using an E8 "torx" socket, remove the stud bolt and cooler compressor assembly.

  7. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01FFWX

      Disconnect the 2 clamps.

    2. Remove the 4 bolts and front No. 1 engine mounting bracket LH.

  8. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A01FEQY

      Remove the 4 bolts and front No. 1 engine mounting bracket RH.

  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01FHP4

      Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.

  10. REMOVE WATER PUMP PULLEY


    1. A01FHMUE03

      Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    2. Remove the 4 bolts and water pump pulley.

  11. REMOVE ENGINE WIRE

  12. REMOVE INJECTOR DRIVER


    1. A01FEVIE02
      Text in Illustration
      *1 Lock Lever
      *a Release
      *b Lock with Connector

      Move the lock levers in the direction indicated by the arrow to release the 3 connector locks. Disconnect the 4 connectors from the injector driver.

    2. A01FE1B

      Remove the bolt, 2 nuts and injector driver.

      Note

      Be careful not to drop or strike the injector driver.

  13. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01FIKA

      Disconnect the throttle motor connector.

    2. Remove the 4 bolts and disconnect the throttle body with motor assembly from the intake air surge tank.

    3. A01FDB1

      Disconnect the 2 water by-pass hoses from the throttle body with motor assembly.

    4. Remove the throttle body with motor assembly and gasket.

  14. REMOVE INTAKE AIR SURGE TANK ASSEMBLY


    1. w/ Cold Start Fuel Injector:

      Remove the cold start fuel injector Click here.

    2. for LHD:

      Disconnect the connector, union to check valve hose, water by-pass hose and 3 wire harness clamps.

    3. for RHD:

      Disconnect the connector, union to check valve hose, water by-pass hose and 4 wire harness clamps.

      A01FEKCE01
      Text in Illustration
      *A for LHD *B for RHD
    4. A01FF7K

      Disconnect the PCV hose.

    5. A01FHAL

      Remove the bolt and No. 3 water by-pass pipe.

    6. A01FIS2

      Remove the bolt and separate the No. 2 surge tank stay from the intake air surge tank assembly.

    7. A01FDD1E01

      Remove bolt A from the intake air surge tank assembly.

    8. Remove the 2 nuts from the intake air surge tank assembly.

    9. Using a 5 mm long socket hexagon wrench, remove the 6 bolts.

    10. A01FHG1

      w/ Swirl Control Valve Position Sensor:

      Detach the wire harness clamp.

    11. A01FGHA

      w/ Cold Start Fuel Injector:

      Detach the fuel tube sub-assembly.

    12. Remove the intake air surge tank assembly and 3 gaskets.

  15. REMOVE NO. 2 SURGE TANK STAY


    1. Remove the bolt and No. 2 surge tank stay.

  16. REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01FGGD

      Remove the bolt, and disconnect the 2 hoses and No. 3 water by-pass pipe.

  17. REMOVE INTAKE MANIFOLD


    1. w/ Swirl Control Valve Position Sensor:

      Disconnect the swirl control valve position sensor connector.

    2. Disconnect the intake air control valve actuator connector.

    3. A01FHOTE01
      Text in Illustration
      *a Front

      Remove the 4 bolts, 4 nuts, intake manifold and 2 gaskets.

  18. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY


    1. A01FGUEE01
      Text in Illustration
      *1 Fuel Tube Sub-assembly

      Remove the fuel pressure pulsation damper and 2 gaskets, and disconnect the fuel tube from the fuel pump.

  19. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. A01FDW5

      Disconnect the No. 2 fuel hose from the No. 1 fuel pipe sub-assembly.

    2. A01FIYU

      Disconnect the 2 fuel hoses.

    3. Remove the 2 bolts and No. 1 fuel pipe sub-assembly.

  20. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Disconnect the fuel high pressure side fuel pump connector.

    2. A01FF05

      Secure the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.

      Note


      • There must be absolutely no free play in the union on the fuel pump side.

      • If the union on the fuel pump side has free play, replace the fuel pump.

    3. A01FFE3

      Remove the 2 bolts on the delivery pipe side.

      Note


      • Do not remove the fuel pipe from the delivery pipe. Only remove the 2 bolts.

      • If the No. 2 fuel pipe is accidentally removed, replace its O-ring, No. 1 backup ring and No. 2 backup ring.

  21. REMOVE FUEL PUMP ASSEMBLY


    1. A01FG6D

      Remove the 2 nuts, fuel pump and fuel pump insulator.

  22. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. A01FHF6

      Remove the 4 bolts and fuel pipe from the fuel delivery pipe sub-assembly.

      Text in Illustration
      A01FJ4N Front

      Note

      Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe O-rings.

    2. Remove the O-rings, backup rings and E-rings from the No. 3 fuel pipe sub-assembly.

  23. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. A01FIBI

      Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe.

      Note

      Pull and remove the No. 2 fuel pipe sub-assembly in a straight line to avoid damage to the seal surface of the delivery pipe O-ring.

    2. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe sub-assembly.

  24. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01FI62

      Disconnect the fuel pressure sensor connector.

    2. Detach the wire harness clamp.

    3. A01FFQGE02
      Text in Illustration
      *1 Nut
      *2 Bolt
      *a Front

      Disconnect the 2 wire harness clamps.

    4. Remove the 2 bolts and 2 nuts.

    5. A01FG46

      With the connectors still connected, disconnect the No. 1 fuel delivery pipe.

      Text in Illustration
      A01FJ4N Front

      Note


      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull and remove the fuel pipe in a straight line without tilting it.

    6. Disconnect the 3 injector connectors.

    7. Remove the 3 injector vibration insulators from the cylinder head.

  25. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01FHO7E04
      Text in Illustration
      *1 Nut
      *2 Bolt
      *a Front

      Disconnect the 3 wire harness clamps.

    2. Remove the 2 bolts and 2 nuts.

    3. A01FERZ

      With the connectors still connected, disconnect the No. 2 fuel delivery pipe.

      Text in Illustration
      A01FJ4N Front

      Note


      • Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).

      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull and remove the fuel pipe in a straight line without tilting it.

    4. Disconnect the 3 injector connectors.

    5. Remove the 3 injector vibration insulators from the cylinder head.

  26. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01FG7SE01

      Secure the delivery pipe in a vise between aluminum plates and pull out the injector in a straight line.

      Note


      • Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe O-ring.

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

    2. Remove the nozzle holder clamps from the injectors.

    3. Remove the O-ring, backup rings and E-ring from the fuel injector.

  27. REMOVE FUEL INJECTOR SEAL


    1. A01FIJD

      Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.

      Note


      • Excessively pinching the injector seal may damage the groove of the injector.

      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

    2. Remove the 2 injector seals from the injector.

  28. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY


    1. A01FHHH

      Remove the bolt and V-bank cover bracket.

  29. REMOVE IGNITION COIL ASSEMBLY


    1. A01FDP5

      Remove the 2 nuts and disconnect the wire harness.

    2. A01FE1W

      Remove the 2 bolts and disconnect the wire harness bracket.

    3. Disconnect the 6 ignition coil connectors.

    4. A01FFGC

      Remove the 6 bolts and the 6 ignition coil assemblies.

  30. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01FE8B

      Disconnect the engine oil level sensor connector.

    2. Remove the 4 bolts and engine oil level sensor.

    3. A01FDY8E01
      Text in Illustration
      *1 Cutting Position
      *2 Supply Part

      Cut off the gasket as shown in the illustration.

    4. Remove the gasket from the engine oil level sensor.

      Tech Tips

      After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

  31. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Disconnect the engine oil pressure switch connector.

    2. A01FH58

      Using a 24 mm deep socket wrench, remove the engine oil pressure switch.

  32. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. Disconnect the engine coolant temperature sensor connector.

    2. A01FDSW

      Remove the engine coolant temperature sensor and gasket.