Removal

PROCEDURE





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. Disconnect Accelerator Cable.
4. Disconnect Throttle Cable.





5. Remove Air Cleaner Hose.
- Disconnect the PCV hose.
- Loosen the 2 hose clamps. and remove the air cleaner hose.





6. Remove V-bank Cover.
- Using a 5 mm hexagon wrench, remove the 2 cap nuts and V-bank cover.
7. Remove Emission Control Valve Set.
Disconnect the following vacuum hoses:





- Vacuum hose from VSV for ACIS; 1
- Vacuum hose from EGR vacuum modulator; 2
- Vacuum hose from EGR valve; 3
- Vacuum hose (from cylinder head rear plate); 4
- Vacuum hose from air intake chamber; 5
- Vacuum hose from fuel pressure regulator; 6

Disconnect the following connectors:





- VSV connector for ACIS; 1
- VSV connector for EGR; 2
- VSV connector for fuel pressure control; 3





Remove the 2 nuts and emission control valve set.





8. Remove No.2 EGR Pipe.
- Remove the 4 nuts, EGR pipe and 2 gaskets.





9. Disconnect Hydraulic Motor Pressure Pipe
- Remove the 2 bolts, and disconnect the pressure pipe from the water inlet and air intake chamber.





10. Remove Air Intake Chamber Assembly.
- Disconnect the 2 PS air hoses.
- Remove the bolt holding the air intake chamber stay to the air intake chamber.

Disconnect the following connectors:





- A/C idle-up valve connector; 1
- EGR gas temperature sensor connector; 2
- Throttle position sensor connector; 3
- IAC valve connector; 4

Disconnect the following vacuum hoses:





- Vacuum hose from charcoal canister; 1





- Vacuum hose from air intake chamber; 2
- 2 vacuum hoses from throttle body; 3

Disconnect the following hoses:





- 2 water bypass hoses from throttle body; 1
- Air assist hose from throttle body; 2

Disconnect the following hoses:





- Brake booster vacuum hose; 1
- Positive Crankcase Ventilation hose; 2
- Actuator vacuum hose; 3
- Disconnect the Data Link Connector 1; g
- Remove the nut and disconnect the 2 ground straps; h





Remove the nut and disconnect the Power Steering pressure tube.
Remove the bolt holding the No.1 engine hanger to the air intake chamber.
Remove the bolt, and disconnect the ground strap.





Using a 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, air intake chamber assembly and gasket.





11. Disconnect Injector Connectors.





12. Remove Air Assist Hoses And Pipe
- Disconnect the air assit pipe from the bracket on the No.1 fuel pipe.
- Remove the air assist hoses from the intake manifold.





13. Disconnect Fuel Inlet And Return Hoses
- Disconnect the fuel return hose from the No.1 fuel pipe.
- Disconnect the fuel inlet hose from the fuel filter.

CAUTION: Catch leaking fuel In a container.

14. Remove Delivery Pipes And Injectors

CAUTION: Be careful not to drop the Injectors when removing the delivery pipes.





- Loosen the 2 union bolts holding the No.2 fuel pipe to the delivery pipes.
- Disconnect the fuel return hose from the fuel pressure regulator.
- Remove the union bolt for the Right Hand delivery pipe. 2 gaskets. 2 bolts, Left Hand delivery pipe together with the 3 injectors and No.2 fuel pipe.
- Remove the union bolt for the Left Hand delivery pipe and 2 gaskets from the No.2 fuel pipe.





- Remove the 3 bolts, Right Hand delivery pipe together with the 3 injectors and No.1 fuel pipe.
- Remove the 4 spacers from the intake manifold.





- Pull out the 6 injectors from the delivery pipes.
- Remove the 2 0-rings and 2 grommets from each injector.