Removal

COMPONENTS FOR REMOVAL AND INSTALLATION

1. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY.

CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.

2. DRAIN ENGINE COOLANT.
3. REMOVE THROTTLE BODY COVER.
- Disconnect the EVAP hose from the hose clamp.
- Remove the cap nut.





- Loosen the 2 bolts, and remove the hose clamp and throttle body cover.





4. DISCONNECT CONTROL CABLES FROM THROTTLE BODY.
- Disconnect the following cables:
- Accelerator cable
- Transmission throttle control cable
- Cruise control actuator cable





5. REMOVE INTAKE AIR CONNECTOR.
- Disconnect the following hoses:
- Air hose from Idle Air Control (IAC) valve
- Air hose (from air control valve on PS pump) from intake air connector
- Remove the bolt holding the intake air connector to the cylinder head cover.





- Loosen the 2 hose clamps.
- Disconnect the intake air connector from the throttle body and air cleaner hose, and remove the intake air connector.





6. REMOVE UPPER HIGH-TENSION CORD COVER.
- Remove the 2 bolts.
- Disconnect the front side claw groove of the upper cord cover from the claw of lower cord cover, and remove the upper cord cover.





7. REMOVE RH ENGINE WIRE COVER.
- Remove the bolt and engine wire cover.





8. REMOVE LH ENGINE WIRE COVER.
- Remove the 2 bolts and engine wire cover.





9. REMOVE RH NO.3 TIMING BELT COVER.
- Disconnect the 2 air control valve hoses.





- Remove the 4 bolts, timing belt cover and 3 gaskets.





10. REMOVE LH NO.3 TIMING BELT COVER.
- Remove the 4 bolts.
- Disconnect the cord grommet from the timing belt cover, and remove the timing belt cover and 3 gaskets.
- Remove the cord grommet from the high-tension cord.





11. REMOVE LOWER HIGH-TENSION CORD COVER.
- Disconnect the high-tension cord from the RH ignition coil.
- Disconnect the high-tension cords from the high- tension cord cover.





- Remove the bolt and cord cover.





12. REMOVE THROTTLE BODY.
- Disconnect the following connectors:
- Throttle position sensor connector
- w/TRAC: Sub-throttle position sensor connector
- w/TRAC: Sub-throttle actuator connector





- Disconnect the following hoses:
- Heater water hose from heater water valve





- Water bypass hose from IAC valve
- Vacuum hose from throttle body





- Remove the 2 bolts and 2 nuts, disconnect the throttle body from the air intake chamber.





- Disconnect the following hoses from the throttle body, and remove the throttle body:
- PCV hose from throttle body
- Water bypass hose from throttle body
- Remove the throttle body gasket.
13. DISCONNECT CONNECTORS.
- Disconnect the following connectors:
- AC valve connector
- EGR valve connector
- VSV connector for fuel pressure control
- VSV connector for EVAP
- EGR gas temperature sensor connector





14. DISCONNECT HOSES.
- Disconnect the following hoses:
- Water bypass hose from IAC valve
- Air hose from air intake chamber
- Vacuum sensing hose from fuel pressure regulator





- Water bypass hose from EGR valve
- Vacuum hose from air intake chamber
- PCV hose from LH cylinder head cover





15. REMOVE AIR INTAKE CHAMBER ASSEMBLY.
- Remove the bolt, stud bolt and accelerator bracket.





- Remove the 2 bolts and gasket, and disconnect the EGR pipe from the air intake chamber.





- Remove the 4 bolts, 8 nuts and transmission throttle cable bracket.
- Disconnect the DLC1 bracket from the air intake chamber.
- Lift the air intake chamber assembly, and disconnect the EGR gas temperature sensor connector.
- Remove the air intake chamber assembly and 4 gaskets.





16. DISCONNECT FUEL INLET HOSE FROM LH DELIVERY PIPE.
- Remove the pulsation damper and 2 gaskets, and disconnect the inlet hose.

CAUTION:
- Put a shop towel under the delivery pipe.
- Slowly loosen the union bolt.

17. DISCONNECT FUEL RETURN HOSE FROM FUEL RETURN PIPE.





18. DISCONNECT EGR PIPE FROM RH CYLINDER HEAD.
- Remove the bolt holding the EGR pipe to the cylinder head, and disconnect the EGR pipe from the RH cylinder head.





19. DISCONNECT ENGINE WIRE FROM INTAKE MANIFOLD.
- Remove the 2 bolts, and disconnect the engine wire from the intake manifold.





20. DISCONNECT ENGINE WIRE FROM DELIVERY PIPES, REAR WATER BYPASS JOINT AND RH CYLINDER HEAD.
- Remove the 4 bolts holding the engine wire to the delivery pipes, and disconnect the engine wire from the delivery pipe.
- Remove the 2 bolts holding the engine wire to the rear water bypass joint, and disconnect the engine wire from the rear water bypass joint.
- Remove the 2 bolts holding the engine wire to the rear side of the RH cylinder head, and disconnect the engine wire from the RH cylinder head.





- Disconnect the 2 engine wire connectors from the connector bracket.
on the front side of the LH delivery pipe.
- Disconnect the 8 injector connectors.





21. REMOVE FUEL RETURN PIPE AND REAR FUEL PIPE.
- Remove the bolt holding the return pipe to the LH cylinder head.
- Remove the union bolt, 2 gaskets and return pipe.

CAUTION:
- Put a shop towel under the return pipe.
- Slowly loosen the union bolt.





22. REMOVE DELIVERY PIPES AND INJECTORS.
- Remove the 4 nuts holding the delivery pipes to intake manifold.
- Remove the connector bracket, the 2 delivery pipes and 8 injectors assembly.

NOTICE: Be careful not to drop the injectors when removing the delivery pipes.

- Remove the 8 insulators and 4 spacers from the cylinder head.
- Pull out the 8 injectors from the delivery pipes.
- Remove the 0-ring and grommet from each injector.