ENGINE UNIT > REMOVAL

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1. REMOVE GENERATOR ASSEMBLY


A217371

  1. Remove the 2 bolts and the generator.



2. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


A217295

  1. Remove the bolt, 2 nuts and the No. 1 exhaust manifold heat insulator.



3. REMOVE MANIFOLD STAY


A217296

  1. Remove the bolt, nut and the manifold stay.



4. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


A217297

  1. Remove the 3 bolts, 4 nuts and the exhaust manifold converter.

  1. Remove the exhaust manifold to head gasket and inlet EGR gasket from the cylinder head.



5. DISCONNECT VENTILATION HOSE


A217301

  1. Loosen the clip and disconnect the ventilation hose from the intake manifold.



6. DISCONNECT NO. 2 WATER BY-PASS HOSE


A217303

  1. Loosen the clip and disconnect the No. 2 water by-pass hose from the throttle body.



7. DISCONNECT NO. 4 WATER BY-PASS HOSE


A217299

  1. Loosen the clip and disconnect the No. 4 water by-pass hose from the EGR valve.



8. REMOVE INTAKE MANIFOLD STAY


A217305

  1. Remove the 2 bolts and the intake manifold stay.



9. REMOVE EGR PIPE CONNECTOR


A217298

  1. Remove the 4 nuts and the EGR pipe connector.

  1. Remove the 2 EGR pipe gaskets from the intake manifold and EGR valve.



10. REMOVE INTAKE MANIFOLD ASSEMBLY


A217306

  1. Remove the 5 bolts, 2 nuts and the intake manifold.



    A203451

  1. Remove the intake manifold to head gasket from the cylinder head.



    A217358

  1. Remove the EGR delivery chamber from the cylinder head.



    A203453

  1. Remove the No. 2 intake manifold to head gasket from the cylinder head.



11. REMOVE NO. 4 ENGINE WIRE


A217355

  1. Disconnect the 2 camshaft timing oil control valve connectors.

  1. Disconnect the 4 ignition coil connectors.

  1. Disconnect the 4 fuel injector connectors.

  1. Remove the ground bolt.

  1. Disengage the 7 clamps and remove the No. 4 engine wire.



12. REMOVE ENGINE OIL LEVEL DIPSTICK


13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


A217307

  1. Remove the 2 bolts and the engine oil level dipstick guide.

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



14. REMOVE EGR VALVE ASSEMBLY


A217308

  1. Remove the bolt, 2 nuts and the EGR valve.

  1. Remove the EGR valve gaskets.



15. REMOVE FUEL DELIVERY PIPE


    A212201

  1. Disconnect the 4 fuel injector assembly connectors.



    A203440

  1. Remove the 2 bolts and delivery pipe together with the 4 injectors.

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



16. REMOVE FUEL INJECTOR ASSEMBLY


    A200111

  1. Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.



    A200115

  1. For reinstallation, attach a tag or label to each injector shaft.

    NOTICE:
    Prevent entry of foreign objects by covering the fuel injectors with plastic bags.



17. REMOVE NO. 1 DELIVERY PIPE SPACER


    A212202

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



18. REMOVE INJECTOR VIBRATION INSULATOR


    A212204

  1. Remove the 4 injector vibration insulators.



19. REMOVE NO. 1 IGNITION COIL

  1. Remove the 4 bolts and remove the 4 No. 1 ignition coils.



20. REMOVE VENTILATION HOSE


A217310

  1. Remove the ventilation hose from the cylinder head cover.



21. REMOVE NO. 2 VENTILATION HOSE


A217309

  1. Remove the No. 2 ventilation hose from the cylinder head cover.



22. REMOVE NO. 1 WATER BY-PASS PIPE


A217312E01

  1. Disengage the No. 2 water by-pass hose from the 3 clamps.
    Text in Illustration 
    *1
    		No. 2 Water By-Pass Hose
    *2
    		No. 1 Water By-Pass Pipe
    *3
    		Water By-Pass Hose

  1. Remove the 3 bolts.

  1. Disconnect the water by-pass hose and remove the No. 1 water by-pass pipe.



23. REMOVE NO. 2 IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)


A217372

  1. Remove the 4 bolts and the No. 2 idle pulley assembly with bracket.



24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


A217328

  1. Remove the 2 bolts and the V-ribbed belt tensioner.



25. REMOVE WIRING HARNESS CLAMP BRACKET


A217334

  1. Remove the bolt and the wiring harness clamp bracket from the cylinder head cover.



    A217373

  1. Remove the bolt and the wiring harness clamp bracket from the cylinder head.



    A217335

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