Removal Steps

FUEL INJECTORS - REMOVAL
1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY.

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

2. REMOVE ENGINE UNDER COVER.

3. DRAIN ENGINE COOLANT.

4. REMOVE THROTTLE BODY.
(a) Disconnect the following hose, cables and connectors from the throttle body:

(1) Air hose
(2) Accelerator cable
(3) Cruise control actuator cable
(4) Throttle position sensor connector
(5) Sub-throttle position sensor connector
(6) Sub-throttle actuator connector

(b) Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the air intake chamber.
(c) Remove the gasket.
(d) Disconnect the following hoses from the throttle body. and remove the throttle body:

(1) EVAP hose
(2) Water bypass hose (from No. 4 water bypass pipe)
(3) Water bypass hose (from cylinder head)
(4) PS air hose

5. REMOVE OIL DIPSTICK AND GUIDE FOR A/T.
(a) Remove the bolt.

(b) Pull out the dipstick guide together with the dipstick.
(c) Remove the 0-ring from the dipstick guide.

6. REMOVE OIL DIPSTICK AND GUIDE FOR ENGINE.

(a) Disconnect the fuel return hose from the clamp of the dipstick guide.
(b) Remove the bolt.
(c) Pull out the dipstick guide together with the dipstick.
(d) Remove the 0-ring from the dipstick guide.

7. REMOVE AIR INTAKE CHAMBER STAY.

- Remove the bolt, nut and chamber stay.

8. DISCONNECT CONTROL CABLE BRACKET FROM AIR INTAKE CHAMBER.
- Remove the 2 bolts, and disconnect the cable bracket from the air intake chamber.

9. DISCONNECT CONNECTORS AND HOSES.
(a) Disconnect the following connectors:

(1) IAC valve connector
(2) Turbo pressure sensor connector
(3) VSV connector for fuel pressure control
(4) VSV connector for EGR

(b) Remove the bolt, and disconnect the engine wire protector from the body.
(c) Disconnect the following hoses:

(1) Air hose from IAC valve
Disconnect the IAC valve pipe from the clamp on the cylinder head cover, and disconnect the air hose from the IAC valve.
(2) Air hose (from air intake chamber) from vacuum pipe on IAC valve pipe
(3) Air hose for EGR from valve pipe

(4) PCV hose from PCV valve
(5) Vacuum sensing hose from fuel pressure regulator

(6) Water bypass hose (from IAC valve) from No. 4 water bypass pipe
(7) EVAP hose (from air intake chamber) from vacuum pipe on manifold stay
(8) EVAP hose (from vacuum pipe on No. 4 water bypass pipe) from No. 2 vacuum pipe
(9) EVAP hose (from charcoal canister) from No. 2 vacuum pipe
(10) P/S air hose from air intake chamber
(11) Brake booster vacuum hose from union on air intake chamber

10. DISCONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR.

(a) Disconnect the connector from the No. 2 vacuum pipe.
(b) Disconnect the sensor connector from the wiring connector.

11. REMOVE EGR PIPE.
(a) Remove the union bolt holding the EGR pipe to the EGR valve.
(b) Remove the 2 bolts, EGR pipe and gasket.

12. REMOVE NO. 4 WATER BYPASS PIPE.

Remove the 2 bolts and water bypass pipe.

13. REMOVE MANIFOLD STAY
Remove the 2 bolts and manifold stay.

14. REMOVE AIR INTAKE CHAMBER ASSEMBLY.

(a) Remove the bolt, and disconnect the ground cable from the intake manifold.
(b) Remove the 2 bolts holding the engine wire protector to the intake manifold.
(c) Disconnect the 2 clamps of the engine wire protector from the brackets.

(d) Remove the 5 bolts. 2 nuts and engine wire bracket. and disconnect the air intake chamber assembly from the intake manifold.

(e) Disconnect the water bypass hose from the IAC valve.
(f) Remove the gasket.

15. DISCONNECT WIRE CLAMPS AND CONNECTORS.
- Disconnect the following connectors and clamps:

(1) 6 injectors connectors
(2) 2 camshaft position sensor connectors
(3) 3 engine wire clamps from injector holders

16. DISCONNECT FUEL INLET PIPE FROM DELIVERY PIPE.

- Remove the union bolt and 2 gaskets, and disconnect the inlet pipe from the delivery pipe.

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

17. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR.
- Remove the union bolt and 2 gaskets, and disconnect the fuel pipe from the pressure regulator.

18. REMOVE DELIVERY PIPE AND INJECTORS.

(a) Remove the 6 bolts and 3 injector holders.

(b) Remove the 6 insulators from the injectors.

(d) Remove the 2 spacers from the intake manifold.

(e) Remove the 6 insulators from the delivery pipe.

19. REMOVE INJECTORS.

(a) Apply gasoline between the delivery pipe and injectors.

(b) Using special service tool (SST# 09268-74010), lift up the 6 injectors.
(c) Remove the insulator and 2 0-rings from each injector.