ENGINE UNIT > REMOVAL

for Preparation Click here



1. REMOVE GENERATOR ASSEMBLY


    A198909

  1. Remove the terminal cap.

  1. Disconnect the connector and 2 harness clamps.

  1. Remove the nut and terminal B.



    A201679

  1. Remove the 2 bolts and 2 brackets.



    A198910

  1. Remove the 2 bolts and fan belt adjusting bar.



    A198911

  1. Remove the bolt and generator assembly.



2. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


A191858

  1. Separate the 2 water by-pass hoses from the hose clamp.

  1. Disconnect the 2 water by-pass hoses.



    A191860

  1. Disconnect the throttle with motor body assembly connector.

  1. Remove the 3 bolts, the nut and the throttle with motor body assembly.



    A191861

  1. Remove the gasket from the intake manifold.



3. REMOVE INTAKE MANIFOLD


A191862

  1. Disconnect the 2 connectors and 4 harness clamps from the intake manifold.

  1. Disconnect the vacuum hose and ventilation hose and remove the 2 bolts from the intake manifold.



    A191863

  1. Remove the 2 bolts, 2 nuts and the intake manifold.



    A191864

  1. Remove the gasket from the intake manifold.



4. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


A201012

  1. Remove the nut, the 2 bolts and the intake manifold insulator.

  1. Remove the gasket from the cylinder head.



5. REMOVE EGR VALVE ASSEMBLY


    A199578

  1. Disconnect the EGR valve connector.

  1. Separate the water by-pass hose.



    A199580

  1. Rotate the EGR valve to avoid contact with the delivery pipe, and remove the EGR valve.

  1. Remove the gasket.



6. REMOVE FUEL DELIVERY PIPE


    A202850

  1. Disconnect the 3 connectors and disengage the 3 harness clamps.



    A202851

  1. Disconnect the 3 fuel injector connectors.



    A202852

  1. Remove the 2 bolts and fuel delivery pipe together with the 3 fuel injectors.

    NOTICE:
    Do not drop the fuel injectors when removing the delivery pipe.



7. REMOVE FUEL PIPE INSULATOR


    A199574

  1. Remove the 2 fuel pipe insulators from the fuel delivery pipe.



8. REMOVE FUEL INJECTOR ASSEMBLY


    A199575

  1. Remove the 3 fuel injectors from the fuel delivery pipe.



9. REMOVE INJECTOR VIBRATION INSULATOR


    A199573

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



10. REMOVE WATER BY-PASS HOSE ASSEMBLY


A191865

  1. Loosen the 2 clips and remove the water by-pass hose assembly.



11. REMOVE NO. 1 RADIATOR HOSE


A191867

  1. Loosen the 2 clips and remove the No. 1 radiator hose.



12. REMOVE NO. 1 IGNITION COIL


A191868

  1. Disconnect the 3 No. 1 ignition coil connectors.

  1. Remove the 3 bolts and the 3 No. 1 ignition coils.



13. REMOVE NO. 2 RADIATOR HOSE


A191880

  1. Loosen the clip and remove the No. 2 radiator hose.



14. REMOVE VACUUM SWITCHING VALVE ASSEMBLY


A203216

  1. Disconnect the vacuum switching valve assembly connector.

  1. Remove the bolt and the vacuum switching valve assembly.



15. REMOVE ENGINE WIRE


A191871

  1. Disconnect all the connectors and disengage the harness clamps.

  1. Remove the 4 bolts and the engine wire.



16. REMOVE IDLER PULLEY


A191872

  1. Remove the 3 bolts and the idler pulley.



17. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY


18. REMOVE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


A191873

  1. Remove the bolt and the oil level dipstick guide sub-assembly.



    A191874

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



19. REMOVE NO. 2 VENTILATION HOSE


A191876

  1. Loosen the clip and remove the No.2 ventilation hose.



20. REMOVE WATER FILLER ASSEMBLY


A191877

  1. Remove the bolt and the water filler assembly.



21. REMOVE WIRE HARNESS CLAMP BRACKET


A191878

  1. Remove the bolt and the wiring harness clamp bracket.



22. REMOVE DRIVE SHAFT BEARING BRACKET


A191879

  1. Remove the 2 bolts and the drive shaft bearing bracket.