REMOVAL
PROCEDURE
1. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Remove the engine oil level dipstick. | |
(b) Remove the bolt and engine oil level dipstick guide.
(c) Remove the O-ring from the engine oil level dipstick guide.
2. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the bolt and V-ribbed belt tensioner assembly. | |
3. REMOVE COMPRESSOR ASSEMBLY WITH MOTOR
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4. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET
(a) Remove the 4 bolts and No. 1 compressor mounting bracket. | |
5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
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6. REMOVE NO. 2 EGR PIPE
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7. REMOVE NO. 2 MANIFOLD STAY
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8. REMOVE MANIFOLD STAY
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9. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
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10. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY
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11. REMOVE WATER BY-PASS PIPE
(a) Remove the 4 bolts, water by-pass pipe and 2 gaskets. | |
12. REMOVE EGR COOLER ASSEMBLY
(a) Slide the hose clamp and disconnect the No. 5 water by-pass hose from the EGR cooler assembly. | |
(b) Remove the bolt and nut, and disconnect the No. 1 EGR pipe from the EGR cooler assembly. | |
(c) Remove the bolt, nut and EGR cooler assembly. | |
(d) Remove the gasket from the No. 1 EGR pipe.
13. REMOVE EGR VALVE ASSEMBLY
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14. REMOVE NO. 3 WATER BY-PASS HOSE
(a) Slide the hose clamp and remove the No. 3 water by-pass hose. | |
15. REMOVE NO. 1 WATER BY-PASS HOSE
(a) Slide the hose clamp and remove the No. 1 water by-pass hose from the cylinder block. | |
16. REMOVE NO. 1 EGR PIPE
(a) Remove the 2 bolts and No. 1 EGR pipe. | |
17. REMOVE ENGINE WATER PUMP ASSEMBLY
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18. REMOVE WATER INLET
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19. REMOVE THERMOSTAT
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20. REMOVE OIL COOLER ASSEMBLY
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21. REMOVE WATER INLET HOUSING
(a) Remove the 3 bolts, nut and water inlet housing from the cylinder block. | |
(b) Remove the gasket. | |
(c) Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the water inlet housing. NOTICE: If a stud bolt is deformed or its thread is damaged, replace it. | |
22. REMOVE INTAKE MANIFOLD
(a) Slide the clamp and disconnect the No. 2 PCV hose from the intake manifold. | |
(b) Slide the clamp and disconnect the purge line hose from the intake manifold. | |
(c) Remove the 6 bolts and intake manifold. | |
(d) Remove the No. 1 intake manifold to head gasket from the intake manifold. | |
23. REMOVE FUEL DELIVERY PIPE
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24. REMOVE INJECTOR VIBRATION INSULATOR
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25. REMOVE SENSOR WIRE
(a) Disconnect the knock control sensor connector. | |
(b) Remove the bolt and sensor wire.
26. REMOVE IGNITION COIL ASSEMBLY
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