Starter Removal

1. (a) Raise vehicle on the hoist.

(b) Attach plastic hose to passenger side engine block drain fitting. Drain coolant into a clean container by loosening the petcock 1 full turn counterclockwise.

NOTE:
In order to prevent any damage, DO NOT loosen more than 1 full turn.

(c) After coolant is drained from block, tighten the petcock and lower vehicle.

(d) Pull fuel door release and loosen fuel cap to release fuel pressure in tank.





(e) Remove battery clamp cover and the air cleaner inlet.

(f) Disconnect the negative battery terminal.





(g) Remove the bolt, 2 cap nuts and the V-bank cover.

(h) Remove the hose retaining clamp and disconnect P/S air control hoses, IAC valve air supply hose, and EVAP hose from canister.

(i) Remove the No.1 air cleaner hose.





(j) Remove one bolt and the intake air connector assembly.

2. Remove Air Intake Chamber Assembly

(a) Disconnect the following cables:

^ Accelerator cable.

^ A/T throttle control cable.

^ Cruise control actuator cable.

(b) Remove the 2 bolts and the accelerator bracket.





(c) Disconnect following connectors:

^ Throttle position sensor connector.

^ w/TRAC: Sub-throttle position sensor connector and Sub-throttle actuator connector.

^ IAC valve connector.

^ EGR valve connector.

^ VSV connector for fuel pressure control.

^ VSV connector for EVAP.

(d) Disconnect the following hoses:

(1) Brake booster vacuum hose from union on air intake chamber.





(2) PCV hose from PCV valve on LH cylinder head.

(3) Disconnect vacuum hose for the fuel pressure VSV at the rear of the air intake chamber.

(4) Water bypass hose from the rear water bypass to EGR valve. (disconnect from EGR valve).

(5) Disconnect the EVAP hose from the VSV for the EVAP.

(6) Water bypass hose to the IAC valve at the thermostat housing.

NOTE:
Use compressed air to blow off any dirt on top of engine before continuing with disassembly. Always wear eye protection when using the compressed air.

(e) Remove the 2 bolts connecting the No.2 EGR pipe to the rear of the air intake chamber.





(f) Remove the 4 bolts and 8 nuts on the air intake chamber assembly.

(g) Position the mounting bracket with the fuel pressure VSV on the right side of the intake manifold.

(h) Raise air intake chamber and disconnect the EGR gas temperature sensor connector.





(i) Lift up the air intake chamber assembly and turn over to the right hand side of the engine. Disconnect the following hoses and remove the air intake chamber assembly and the 4 gaskets.

^ Disconnect the water bypass hose to the rear water bypass from the throttle body.





^ Disconnect the PCV hose to RH cylinder head from the throttle body.

(j) Cover up intake manifold ports to prevent any dirt from entering.

(k) Remove 2 nuts connecting the No.2 EGR pipe to rear water bypass and lift off No.2 EGR pipe with the 2 gaskets.

(l) Cover the hole of the No.2 EGR pipe to prevent any dirt from entering.





3. Disconnect Fuel Return Hose

(a) Disconnect the fuel return hose from the fuel pressure regulator.

4. Remove Heater Hoses

(a) Disconnect the heater water hose from the water bypass pipe.

(b) Disconnect the other heater water hose from the heater water valve assembly.

5. Disconnect Engine Wire Harness from Fuel Rails and Rear Water bypass





(a) Disconnect the A/T throttle cable from the clamps on the engine hanger and engine wire protector.

(b) Remove the 2 bolts and disconnect the engine wire harness from the rear water bypass.

(c) Remove the 2 bolts, and disconnect the engine wire harness from the RH fuel rail.





(d) Loosen, but do not remove the fuel return pipe mounting bolt from the rear of LH cylinder head.

(e) Remove the fuel return pipe mounting bolt from the rear water bypass under engine wire harness.

(f) Disconnect the following:

^ DLC1 from bracket on LH fuel rail.

^ 2 engine wire connectors (EA1 & EA2 for LS400 and EC1 & EC2 for SC400) from connector mounting bracket on LH fuel rail.

^ Engine wire clamp from wire bracket on LH fuel rail.





6. Remove Intake Manifold Assembly

(a) Disconnect the 8 injector connectors.

(b) Remove the 6 bolts, 4 nuts, the intake manifold assembly and 2 gaskets.

NOTE:
When removing the intake manifold, first clear the wire bridge at left front corner, second, clear the wire harness at right front corner, then lift the rear of the manifold up and forward to clear the fuel return pipe and wire harness at the rear of the engine.





(c) Carefully turn the intake manifold over on top of the LH strut tower with fuel hose still connected.

NOTE:
Place cardboard over LH strut tower and battery (On SC400, also cover the ignitor) prior to placing the manifold.





(d) Place SST protective covers over intake ports and reinstall the nuts to keep the covers in place while you are working in the engine valley.

NOTE:
DO NOT disconnect knock sensor connectors from knock sensors.





7. Remove Water Bypass Pipe

(a) Disconnect the wire clamp from the bracket on the water bypass pipe.

(b) Remove the water bypass pipe mounting bolt.

(c) Pull out the water bypass pipe from the back of the water pump.





(d) Position water bypass pipe to the right side with the rear end behind passenger side valve cover.




8. Remove Rear Water Bypass





(a) From the new SST set, select the phased six point box wrench that provides the best positioning of the tool for loosening the lower bolt for the top end of No.1 EGR pipe.





(b) Position SST under the rear water bypass (between starter and loosened water bypass pipe) and onto the lower bolt for the upper end of the No.1 EGR pipe, slide the adjustable handle over the end of the wrench. Reach over the rear water bypass and use your finger tip to ensure that the wrench remains securely seated on the bolt head as you apply torque.

NOTE:
To take advantage of this SS1; it is necessary to alternate use after each partial turn of the bolts.

(c) Remove upper bolt of No.1 EGR pipe by accessing with SST behind rear water bypass.

(d) Remove the 4 nuts holding the rear water bypass to the cylinder heads.

(e) Remove the rear water bypass and 3 gaskets from under the engine harness. (No.1 EGR pipe top gasket and 2 water bypass gaskets).

NOTE:
Lift the rear water bypass and then roll the bottom towards the front of engine for easier removal. Be careful not to bend the No.1 EGR pipe as it will become difficult to reinstall.





9. Starter Removal

(a) Carefully pry open plastic cover on starter cable mounting stud.

(b) Remove the starter cable mounting nut.





(c) Disconnect the starter connector.

NOTE:
Make sure the connector is released before pulling it out.

(d) Remove the bolt, and disconnect the wire clamp from the starter.

(e) Remove the 2 starter mounting bolts from top rear of the engine.

NOTE:
Use a 3/8 inch drive flex-head ratchet and a shallow 14 mm socket to break the bolts loose. Then use a 114 inch drive flex-head ratchet to back the bolts out as far as possible without trapping the ratchet between the bolt and the firewall.





While removing the starter mounting bolts, be careful not to bend the No.1 EGR pipe as it will become difficult to reinstall.

(f) Remove the starter from the cylinder block.

(g) Remove water bypass pipe.

NOTE:
First install supplied cap on rear end of pipe to prevent coolant spillage. Pour coolant from pipe into the container of coolant drained from the engine block.





COMPONENTS FOR DISASSEMBLY AND ASSEMBLY