ENGINE UNIT REMOVAL

  1. REMOVE ENGINE HANGERS

    1. Remove the 2 bolts and 2 engine hangers.

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      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No .2 Engine Hanger

  2. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    1. Remove the engine oil level dipstick.

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    2. Remove the bolt and engine oil level dipstick guide.

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

  3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    1. Remove the 4 bolts and No. 1 exhaust manifold heat insulator.

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  4. DISCONNECT NO. 1 WATER BY-PASS HOSE

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

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  5. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

    1. Disconnect the 2 hoses.

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    2. Disconnect the throttle body connector.

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

    4. Remove the 4 bolts and the throttle body with fuel tube bracket.

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    5. Remove the gasket from the intake manifold.

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  6. REMOVE NO. 2 EGR PIPE

    1. Remove the 2 bolts, 2 nuts and No. 2 EGR pipe.

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    2. Remove the 2 gaskets.

  7. REMOVE MANIFOLD STAY

    1. Remove the bolt, nut and manifold stay.

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  8. REMOVE NO. 2 MANIFOLD STAY

    1. Remove the bolt, nut and No. 2 manifold stay.

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  9. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Remove the 5 nuts and exhaust manifold converter sub-assembly.

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    2. Remove the gasket.

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  10. REMOVE EGR COOLER ASSEMBLY

    1. Disconnect the water by-pass hose.

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    2. Remove the bolt and nut.

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    3. Separate the 2 clamps.

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    4. Disconnect the No. 4 water by-pass hose and No. 6 water by-pass hose.

    5. Remove the bolt, nut and separate the EGR cooler assembly from the engine.

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  11. REMOVE NO. 1 EGR PIPE

    1. Remove the 2 bolts and No. 1 EGR pipe.

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  12. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    1. Disconnect connector B.

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      Text in Illustration
      *1 Green-colored Lock

    2. Release the green-colored lock and disconnect connector A as shown in the illustration.

      CAUTION:

      Wear insulated gloves when performing the following steps.

      Note

      Insulate the connector by sealing it with tape.

    3. Remove the bolt and 2 nuts and compressor with motor assembly.

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    4. Using an E8 "TORX" socket, remove the 2 stud bolts.

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  13. REMOVE ENGINE WATER PUMP ASSEMBLY

    1. Disconnect the harness clamp.

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    2. Disconnect the connector from the engine water pump assembly.

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    3. Remove the 5 bolts and engine water pump assembly.

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    4. Remove the gasket from the engine water pump assembly.

  14. REMOVE WATER INLET SUB-ASSEMBLY

    1. Remove the 2 bolts and water inlet sub-assembly.

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    2. Remove the gasket from the water inlet sub-assembly.

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  15. REMOVE WATER INLET HOUSING

    1. Remove the bolt and harness clamp bracket from the cylinder block.

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    2. Remove the bolt and harness clamp bracket from the water inlet housing.

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    3. Remove the 3 bolts, nut, and water inlet housing.

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      Text in Illustration
      *1 Bolt
      *2 Nut

    4. Remove the gasket.

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    5. Using an E8 "TORX" socket wrench, remove the stud bolt from the cylinder block.

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    6. Using an E5 "TORX" socket wrench, remove the stud bolt from the water inlet housing.

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  16. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

    1. Remove the 4 bolts and No. 1 compressor mounting bracket.

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  17. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

    1. Disconnect the 4 fuel injector connectors.

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    2. Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors.

      Note

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

    3. Remove the 2 fuel delivery spacers from the cylinder head.

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    4. Remove the 4 injector vibration insulators from the cylinder head.

  18. REMOVE INTAKE MANIFOLD

    1. Remove the intake manifold from the vehicle.

    2. Remove the gasket from the intake manifold.

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    3. Remove the bolt and wire harness clamp bracket.

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    4. Remove the vacuum hose from the intake manifold.

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    5. Remove the fuel vapor feed hose from the intake manifold.

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  19. REMOVE SENSOR WIRE

    1. Disconnect the knock control sensor connector.

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    2. Remove the bolt and knock control sensor wire.

  20. REMOVE IGNITION COIL ASSEMBLY

    1. Disconnect the 4 ignition coil assembly connectors.

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    2. Remove the 4 bolts and 4 ignition coil assemblies.

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